Spring-Loaded Busbar for Laser Welding
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Solution Overview
Problem
Ensuring secure and efficient electrical connections between busbars and battery cell terminals is challenging due to the need for planar contact and mechanical fixtures, which can fail under vibration and temperature changes, potentially causing short circuits and safety issues.
Innovation Solution
A spring-loaded busbar design with preloaded tabs that bend to achieve planar contact and utilize notches as fuses to prevent overheating, and dimples for precise welding, ensuring reliable and secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical fixtures are used to secure busbar connections, then connection stability is improved, but device complexity increases and reliability decreases due to potential failure under vibration and temperature changes
Solution Approach 1:
The patent replaces mechanical fixtures with laser welding to secure the busbar to the battery terminal. The busbar features pre-formed contact surfaces with dimples that align with protrusions on the terminal, enabling direct laser welding without mechanical fasteners. This substitution eliminates the complexity and potential failure points of mechanical fixtures while improving connection reliability through permanent weld bonds that resist vibration and thermal expansion.
2Manufacturing precision
If planar contact is ensured through mechanical means, then welding quality is improved, but the risk of overheating and short circuits increases due to potential connection failures
Solution Approach 1:
The busbar contact surface is pre-formed with dimples during manufacturing that correspond to protrusions on the battery terminal. This preliminary geometric configuration ensures precise alignment and planar contact before the welding operation, enabling high-quality welds. The pre-formed features eliminate the need for complex alignment fixtures and ensure consistent welding quality while reducing the risk of poor connections that could lead to overheating and short circuits.
3Reliability
If spring-loaded design with preloaded tabs is used, then contact reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The busbar incorporates pre-formed geometric features (dimples and angled contact surfaces) that are integrated into the busbar body during manufacturing. These features create a spring-loaded effect where the busbar naturally applies preloaded contact force to the terminal when positioned, improving contact reliability. The spring-loaded functionality is achieved through geometric design rather than separate mechanical components, maintaining manufacturing simplicity while ensuring reliable electrical contact.
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 enhances the quality of welds, improves contact reliability, and reduces the risk of short circuits and overheating, ensuring safe and efficient battery operation.
Implementation Method 1
A spring-loaded busbar for laser welding operation
Implementation Method 2
A spring-loaded busbar for laser welding operation
Data Source
AI summary
A spring-loaded busbar has a first portion divided from a second portion by a first pair of notches and a third portion divided from the second portion by a second pair of notches. The second portion is bent relative to the first portion and the third portion is bent relative to the second portion. The busbar is configured to deform elastically when pressed against an electrical cell to ensure proper contact between the busbar and the cell before the busbar is welded to the cell.