Laser Welding Plate With Moveable Tips for Cell Height Variation
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Solution Overview
Problem
Laser welding of bus bars to battery cells in energy storage systems is compromised by varying cell heights due to manufacturing tolerances, leading to uneven electrical contact and poor welding quality.
Innovation Solution
The use of welding plates with moveable tips and elastomer compressors that adjust to individual cell heights, combined with a backer plate to ensure even cell height and secure bus bar contact, along with monitoring lasers for weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed welding plate is used to press bus bars on cells, then the welding pressure is uniform, but the varying cell heights cause uneven welding and poor electrical contact
Solution Approach 1:
The welding plate is segmented into multiple independent tip elements, each capable of independent vertical movement. This segmentation allows each tip to adapt to the height of individual cells while maintaining uniform welding pressure across all contact points, resolving the contradiction between welding quality and adaptability to height variation.
Solution Approach 2:
The welding plate incorporates dynamic elements (tips that can move vertically) rather than a completely rigid structure. The elastomer components enable the tips to dynamically adjust their position based on cell height variations, allowing the system to maintain consistent welding pressure despite manufacturing tolerances in cell dimensions.
2Adaptability or versatility
If the welding plate is made rigid to maintain stable contact, then the structure is simple, but it cannot accommodate varying cell heights
Solution Approach 1:
The welding plate utilizes elastomer elements that function as flexible components. These elastomeric tips can deform and adjust to varying cell heights while maintaining structural integrity, providing the necessary adaptability without requiring complex mechanical adjustment mechanisms.
Solution Approach 2:
The elastomer properties (durometer rating, compression characteristics) are carefully selected to provide the optimal balance between flexibility and structural stability. By changing the material parameters of the elastomer, the system achieves adaptability to height variations while maintaining a relatively simple overall structure.
3Force
If elastomer with high durometer rating is used, then the welding pressure is maintained, but the tip cannot adjust to cell height variations
Solution Approach 1:
The elastomer durometer rating is specifically selected within an optimal range that balances two competing requirements: sufficient hardness to maintain welding pressure and sufficient softness to allow tip movement for height adjustment. This parameter optimization resolves the contradiction between maintaining force and achieving adaptability.
Solution Approach 2:
The elastomer elements provide dynamic response to varying cell heights while maintaining welding pressure. The material's viscoelastic properties allow it to deform under compression to accommodate height variations while recovering to maintain consistent contact force during the welding process.
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
Ensures consistent and high-quality laser welding by accommodating varying cell heights, maintaining intimate contact and enabling effective electrical connections between bus bars and cells.
Implementation Method 1
Each recess comprises an elastomer configured to compress under a force... The elastomer has a durometer rating less than a predetermined threshold
Implementation Method 2
The terminals are typically attached via laser welding... Each tip has a central opening forming a welding channel
Implementation Method 3
Each second opening and the central opening of the tip may further comprise an extended section configured to receive light from a monitoring laser for monitoring a quality of a weld
Data Source
AI summary
Welding plates and a welding system are provided. A welding plate comprises a first portion and a second portion. The first portion comprises a plurality of recesses. Each recess comprises an elastomer configured to compress under a force and a tip. A proximal end of the tip is in contact with the elastomer. The elastomer has a durometer rating less than a predetermined threshold. The second portion may be mounted to the first portion. The second portion has a plurality of first openings. Each first opening corresponds to a recess. A respective tip extends through a respective first opening. Each tip is slidably mounted within the welding plate. Each tip has a central opening forming a welding channel.