Laser Welding Printed Circuit Board to Cell Controller
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical energy storage systems face challenges in achieving compact and lightweight designs while maintaining high energy density, which limits their application in reducing the mass of devices and extending vehicle range.
Innovation Solution
The integration of a printed circuit board cohesively connected to cell controllers via laser welding, with a housing part and alignment features, allows for secure and efficient connections between the control unit and electrical energy storage cells, reducing energy input and enabling precise alignment for improved energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (e.g., soldering) are used to connect the printed circuit board to cell controllers, then reliable electrical connection is achieved, but excessive energy input causes critical temperature rise in electrical energy storage cells
Solution Approach 1:
The patent replaces the traditional soldering process with laser welding technology. The laser welding unit directly welds conductor tracks to contact pads through the housing part and transparent film, eliminating the need for soldering materials and processes. This substitution reduces energy input and prevents critical temperature rise in the electrical energy storage cells while maintaining reliable electrical connections.
Solution Approach 2:
The patent introduces a transparent film as an intermediary element that allows the laser beam to pass through while providing a protective barrier. The housing part with third cutouts serves as another intermediary structure that enables laser access to the connection points. These intermediary elements facilitate the laser welding process without direct contact with the electrical energy storage cells, preventing temperature-critical situations.
2Weight of moving object
If the printed circuit board is cohesively connected to cell controllers, then compact and lightweight design is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the housing part structure with the connection assembly function. The housing part includes third cutouts that serve dual purposes: providing structural support and enabling laser beam access for welding the printed circuit board to cell controllers. This integration reduces the number of separate components and simplifies the manufacturing process while achieving compact design.
Solution Approach 2:
The patent performs preliminary alignment of the printed circuit board with electrical energy storage cells using positively locking connections and alignment features before the final cohesive connection. This preliminary positioning ensures accurate alignment of connection points, simplifying the subsequent laser welding process and reducing manufacturing complexity.
3Manufacturing precision
If alignment features are implemented for precise positioning, then connection accuracy is improved, but device complexity increases
Solution Approach 1:
The patent designs alignment features that serve multiple functions: the projections on electrical energy storage cells and corresponding cutouts in the printed circuit board provide both mechanical alignment for precise positioning and structural support for the connection assembly. This multi-functionality reduces the need for separate alignment mechanisms, thereby reducing overall device complexity while maintaining high manufacturing precision.
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 results in a more compact and lightweight electrical energy storage system with enhanced energy density, enabling reduced mass and extended range in devices and vehicles.
Implementation Method 1
a laser welding unit, in particular arranged in the housing part, for laser-welding a conductor track (45) to a contact pad (43) of a cell controller (31)
Implementation Method 2
The third cutouts are closed by means of a transparent film, in particular a laser-transparent film. In this case, the film is transmissive to the laser beam used for the laser welding.
Data Source
AI summary
Electrical energy store (1), device and/or vehicle and method for producing an electrical energy store (1) comprising a control unit (11) and electrical energy storage cells (2), each comprising a cell controller (31), wherein the control unit (11) comprises a printed circuit board which is cohesively connected to the respective cell controller (31) of each electrical energy storage cell (2).