Cell Connector Welding Layout for Low-Heat Accumulator Assemblies
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Solution Overview
Problem
Existing accumulator assembly welding techniques, such as laser welding, result in high thermal input damaging plastic components and requiring excessive structural space, and are not cost-effective due to high system technology investments.
Innovation Solution
The accumulator assembly employs a cell connector element welded at specific locations based on anticipated current density, using reduced weld seam lengths and geometries like continuous or segmented part-circles, semi-circles, and straight lines to minimize thermal input and structural space, while maintaining consistent contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is used to connect cell connector element to connection element, then welding strength is improved, but thermal input damages plastic components and increases structural space requirements
Solution Approach 1:
The patent applies local quality by concentrating weld locations specifically at areas with high current density on the connection elements. Instead of uniform welding across the entire surface, weld spots are strategically placed only where electrical current flows most intensely, thereby providing sufficient welding strength at critical locations while minimizing unnecessary thermal input to surrounding plastic components.
Solution Approach 2:
The welding process is segmented into multiple discrete weld locations rather than a continuous weld seam. This segmentation allows the thermal energy to be distributed across separate points in time and space, preventing excessive heat accumulation in any single area and reducing thermal damage to adjacent plastic components while maintaining overall welding strength.
2Productivity
If laser beam welding is used, then welding speed is improved, but system technology investments increase significantly
Solution Approach 1:
The patent applies partial action by using only enough welding (multiple discrete spots) to achieve the required connection strength, rather than excessive welding coverage. This partial welding approach maintains adequate productivity while significantly reducing the complexity and cost of system technology compared to full-surface laser beam welding.
3Temperature
If weld seam length is reduced to minimize thermal input, then thermal load on accumulator cells is reduced, but welding strength may be compromised
Solution Approach 1:
The patent resolves this contradiction by applying local quality - placing multiple weld spots precisely at locations with high current density. This ensures that the limited weld material is concentrated where it is most needed for electrical and mechanical strength, while minimizing total weld seam length and associated thermal load on the accumulator cells.
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 approach reduces the thermal load on accumulator cells and nearby plastics, halves the weld seam surface area, decreases production cycle time, and lowers system technology investments, allowing for smaller component designs and increased structural freedom.
Implementation Method 1
The cell connector element is welded at least to one of the electrical connection elements of one of the accumulator cells by way of a plurality of weld locations
Data Source
AI summary
An accumulator assembly includes first and second accumulator cells, each of which includes at least one electrical connection element. The accumulator assembly also includes a cell connector element which electrically connects the electrical connection element of the first accumulator cell with the electrical connection element of the second accumulator cell. The cell connector element is welded at least onto one of the electrical connection elements via a plurality of welding locations. The number and the location of the welding locations are selected according to an expected current density in such a way that more welding locations are arranged at locations with a higher expected current density, and zero or fewer welding locations are arranged at locations with a lower expected current density.