Folded Cell Connector for Tolerance-Compensated Conductor Welding
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Solution Overview
Problem
Existing methods for connecting galvanic cell output conductors face challenges such as gaps due to tolerances and material differences, requiring precise positioning and high clamping forces, which can lead to incomplete welds and mechanical stress, especially when connecting cells with height offsets.
Innovation Solution
A cell connector with a strip-shaped element featuring multiple portions that fold into a receptacle to align and clamp output conductors securely, allowing for reliable welding while compensating for tolerances and reducing mechanical stress, and featuring a welding window for improved access and reduced thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high clamping force is applied to close gaps between output conductors, then welding quality improves, but the cell frame stability is compromised
Solution Approach 1:
The clamping function is segmented from the cell frame structure. Instead of using the cell frame itself as the clamping device, a separate clamping mechanism is introduced that can apply localized force only where needed at the welding position, without transmitting stress to the cell frame structure.
Solution Approach 2:
A clamping element acts as an intermediary between the welding tool and the output conductors. This intermediary component applies the necessary clamping force to ensure good contact between conductors during welding, while the cell frame remains unloaded and maintains its structural stability.
2Reliability
If output conductors are pressed together with high force to eliminate gaps, then electrical contact improves, but mechanical stress on the connection increases
Solution Approach 1:
The clamping force is applied dynamically only during the welding process rather than being a permanent static load. The clamping element is positioned to provide contact during welding, then releases or reduces force afterward, avoiding continuous mechanical stress on the connection while ensuring good electrical contact during the critical welding phase.
3Productivity
If laser welding is used to connect output conductors, then welding speed and precision improve, but the risk of welding through into the cell frame increases
Solution Approach 1:
The clamping element is positioned in advance to create optimal contact between output conductors before the laser welding begins. This preliminary alignment ensures that the laser energy is concentrated on the conductor interface rather than being absorbed or scattered, allowing for faster welding at lower power settings that reduce the risk of burning through into the cell frame.
4Adaptability or versatility
If cell connector is bent to compensate for height offset, then connection flexibility improves, but positioning precision requirements increase
Solution Approach 1:
The clamping element is designed with adjustable geometric parameters, including bend angles and positions, that can be adapted to compensate for height offsets between cells. By varying these parameters, the system achieves flexibility in connecting cells with different geometries while maintaining precise positioning through controlled deformation of the clamping element itself rather than requiring precise positioning of rigid components.
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 solution ensures a reliable, high-quality weld connection with reduced effort and increased process safety, allowing for flexible connection of different cell geometries and easier inspection of weld seams, while minimizing the risk of thermal damage and mechanical stress.
Implementation Method 1
The output conductors are welded together for a robust connection
Implementation Method 2
Output conductors of pouch cells are typically connected by means of laser welding
Data Source
AI summary
A cell connector for interconnecting output conductors and/or wires includes a strip-shaped element with at least five portions. A first portion forms a first half of a closure element, the second portion forms a first clamping surface, the third portion forms a deflection element, the fourth portion forms a second clamping surface, and the fifth portion forms a second half of the closure element. The third portion is configured to enable the first portion and the second portion to be folded over relative to the fourth portion and the fifth portion such that, in a folded-up state of the strip-shaped element, a portion of the first and a portion of the second clamping surfaces lie opposite each other and form a receptacle and, in the folded-up state, the first portion and the fifth portion can be interconnected to fix the strip-shaped element in the folded-up state.