Battery Welding Mask With Spring Clamps for Faster Cell Alignment
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Solution Overview
Problem
The process of laser welding battery cells to current collectors in electric vehicle battery packs is time-consuming due to the small areas that need to be welded, requiring high precision and extensive movement of the welding device, especially when dealing with a large number of battery cells.
Innovation Solution
A mask with openings and clamps is used to securely clamp battery cells to current collectors before welding, allowing the welding device to weld through the openings without moving in the z-direction, thereby reducing the cycle time and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the welding device moves to each battery cell individually to perform welding, then welding precision can be maintained, but the cycle time increases significantly
Solution Approach 1:
The mask is pre-configured with multiple clamps positioned at specific locations corresponding to different battery cells. The clamps are adjusted and secured before the welding process begins, allowing the welding device to remain stationary and perform multiple welds without moving or re-clamping between cells.
Solution Approach 2:
The mask incorporates adjustable clamps that can be dynamically positioned and secured at different locations. The clamps are designed to be adjustable during setup but fixed during operation, providing both flexibility for different cell configurations and stability during welding.
2Productivity
If the welding device remains stationary to reduce cycle time, then productivity improves, but welding precision may be compromised
Solution Approach 1:
The mask acts as an intermediary device that brings the clamping function to the battery cells rather than requiring the welding device to move. The mask with its positioned clamps serves as a fixed reference frame that maintains precise positioning of battery cells relative to the stationary welding device.
3Measurement precision
If clamping is performed repeatedly for each welding operation, then positioning accuracy is maintained, but the process time increases
Solution Approach 1:
All clamping operations are performed in advance before welding begins. The mask's clamps are positioned and secured on each battery cell during setup, eliminating the need for repeated clamping during the welding sequence. This preliminary clamping maintains positioning accuracy while dramatically reducing process time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly reduces the time required to weld battery cells and current collectors together, allowing for faster battery manufacturing by minimizing the need for repeated clamping and movement of the welding device, and enabling the welding of multiple cells in a single sequence.
Implementation Method 1
a spring positioned with the clamp and the plate, the spring to cause the clamp to align the battery cell with a current collector
Implementation Method 2
A welding device can weld the battery cell and the current collector through the opening
Data Source
AI summary
An apparatus is provided. The apparatus can include plate including an opening. The apparatus can include a clamp to couple a battery cell with the plate with a terminal of a cell of the battery module at least partially exposed through the opening. The apparatus can include a spring positioned with the clamp and the plate, the spring to cause the clamp to align the battery cell with a current collector.