Linear Laser Welding Busbar Joint Strength
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Solution Overview
Problem
Existing busbar manufacturing methods, such as spot welding, often result in insufficient joint strength between connected members.
Innovation Solution
A busbar configuration featuring a linear welding area that extends between both ends of platy members, utilizing laser welding with multiple beams of different wavelengths to enhance joint strength and reduce electric resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spot welding is used to connect members, then the manufacturing process is simple, but the joint strength is insufficient
Solution Approach 1:
The welding process is segmented into multiple stages: pre-heating stage, welding stage, and post-heating stage. Multiple laser beams are used simultaneously or sequentially to create a complex thermal field that ensures proper melting, mixing, and solidification of the joint, thereby achieving high joint strength without excessive overall process complexity
Solution Approach 2:
A pre-heating stage is performed before the actual welding to raise the temperature of the workpiece to an optimal range (100-500°C). This preliminary action prepares the material for better weldability, reduces thermal shock during welding, and prevents defects, thereby improving joint strength while maintaining process efficiency
2Reliability
If traditional welding methods are used, then the process is straightforward, but sputtered material and blow holes occur
Solution Approach 1:
A pre-heating stage is implemented before welding to gradually raise the workpiece temperature and prepare the material. This cushioning approach prevents sudden thermal expansion and contraction that cause sputtering and blow holes, thereby improving welding quality by eliminating these harmful factors
Solution Approach 2:
The invention dynamically adjusts multiple parameters including laser power, scanning speed, and focal position during different welding stages. By optimizing these parameters, the thermal field is controlled to prevent excessive vaporization and material ejection, thereby eliminating sputtered material and blow holes while ensuring high welding quality
3Quantity of substance
If conventional welding is applied, then manufacturing cost is controlled, but electric resistance remains high
Solution Approach 1:
Multiple laser beams are merged to create a concentrated and distributed thermal field simultaneously. This combined approach ensures complete melting and intimate mixing of the joint materials, creating a low-resistance weld without requiring additional post-processing steps, thereby reducing electric resistance while maintaining cost-effectiveness
Solution Approach 2:
The invention transitions from conventional single-point welding to a three-dimensional thermal field distribution using multiple laser beams at different positions and angles. This dimensional approach ensures uniform heating and complete penetration throughout the joint volume, eliminating high-resistance pathways and achieving low electric resistance
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 proposed solution achieves higher joint strength and reduced electric resistance compared to traditional spot welding, while also reducing manufacturing costs and minimizing welding failures like sputtered material and blow holes.
Implementation Method 1
forming the welding area by application of a laser light including a plurality of beams
Implementation Method 2
forming the welding area by application of a laser light including a plurality of beams
Data Source
AI summary
A busbar includes: a plurality of members that are platy; and a welding area in which two of the members are welded, the welding area being linear and extending in a first direction, the welding area being provided approximately between both ends of at least one of the two members in the first direction.