Bus-Bar Weld Structure With Intermediate Layer for Stronger Joints
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Solution Overview
Problem
The existing bus-bar connection structures are prone to failure under excessive external force, compromising the connection strength between the bus bar and the external terminal due to the weakness of the weld portion.
Innovation Solution
A bus-bar connection structure is designed with a weld portion that includes a first weld layer in the bus bar, a second weld layer in the terminal, and an intermediate weld layer in the clearance between them, where the intermediate weld layer has a larger minimum width than the first weld layer, enhancing the connection strength. This structure also features a recess in the bus bar and a through hole for air flow during welding, ensuring a robust weld shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a weld portion connects the bus bar to the external terminal, then electrical connection is established, but the weld portion is weak and breaks under excessive external force
Solution Approach 1:
The invention transitions from a conventional single-layer weld structure to a multi-layer weld structure with depth dimensionality. The weld portion includes a first weld layer in the bus bar, a second weld layer in the terminal, and an intermediate weld layer in the clearance, creating a three-dimensional distributed connection that significantly enhances strength and reliability under external force.
2Ease of manufacture
If a clearance is provided between the bus bar and terminal portion, then welding is facilitated, but the weld portion becomes weaker
Solution Approach 1:
The invention introduces an intermediate weld layer as a mediator substance in the clearance between the bus bar and terminal portion. This intermediate layer fills the clearance space and creates a bonding bridge between the first weld layer in the bus bar and the second weld layer in the terminal, thereby maintaining welding ease while significantly strengthening the overall weld structure.
3Strength
If the intermediate weld layer has larger minimum width than the first weld layer, then connection strength is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The invention specifies that the minimum width of the intermediate weld layer in the direction orthogonal to the predetermined direction is larger than the minimum width of the first weld layer in the same direction. This parameter change optimizes the stress distribution and connection strength, with the intermediate layer acting as a reinforcement zone that compensates for the clearance gap.
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
The enhanced weld shape and structure significantly increase the connection strength between the bus bar and the terminal, preventing fractures and ensuring a stable connection even under external forces.
Implementation Method 1
a weld portion that connects the terminal portion and the bus bar
Implementation Method 2
when a molten metal of the bus bar enters the clearance during welding of the bus bar and the terminal portion, air can flow out from the clearance to the outside
Data Source
AI summary
A bus-bar connection structure includes: a terminal portion having a first facing surface; a bus bar having a second facing surface that faces the first facing surface with a clearance being provided between the second facing surface and the first facing surface in a predetermined direction; and a weld portion that connects the terminal portion and the bus bar. The weld portion has: a first weld layer provided in the bus bar; a second weld layer provided in the terminal portion; and an intermediate weld layer disposed in the clearance, the intermediate weld layer connecting the first weld layer and the second weld layer. The weld portion has a cross sectional shape in which a minimum width of the intermediate weld layer in a direction orthogonal to the predetermined direction is larger than a minimum width of the first weld layer in the direction orthogonal to the predetermined direction.