Z-Shaped Weld Bead for Battery Busbar Connection
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Solution Overview
Problem
Conventional battery assemblies for electrified vehicles face challenges in reliably connecting battery cells to achieve high voltage and power levels, with existing weld methods prone to crack propagation, weld defects, and stress concentrations.
Innovation Solution
A battery assembly featuring Z-shaped weld beads that secure busbars to terminals, providing improved connection strength, reduced stress concentrations, and increased electrical conductivity through a pattern of parallel and diagonal legs with curved ends, and spaced-apart weld beads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional weld methods are used to connect busbars to terminals, then the connection is simple to manufacture, but the weld joints are prone to crack propagation and stress concentrations
Solution Approach 1:
The weld bead is formed with a Z-shaped pattern featuring curved ends instead of sharp angles. The curved ends of the weld bead reduce stress concentrations by distributing mechanical loads more evenly across the joint, preventing crack initiation and propagation while maintaining connection reliability
Solution Approach 2:
The weld bead is segmented into multiple passes forming the Z-pattern, with the weld deposited in a systematic sequence that creates distinct segments. This segmentation allows for better control of the welding process, reduced heat accumulation, and improved distribution of residual stresses throughout the joint
2Strength
If conventional weld patterns are used, then the welding process is fast and simple, but the connection strength and electrical conductivity are insufficient
Solution Approach 1:
The welding process follows a periodic Z-shaped path, systematically moving the weld pool across the joint area in a repeating pattern. This periodic action ensures uniform heat distribution, consistent penetration depth, and homogeneous weld metal distribution, resulting in improved connection strength and electrical conductivity
Solution Approach 2:
The Z-shaped weld pattern maintains continuous welding action across the entire joint surface, ensuring complete coverage and consistent metallurgical bonding throughout. The continuous deposition process prevents cold laps and ensures uniform electrical and mechanical properties across the connection
3Manufacturing precision
If simple weld beads are used, then the manufacturing process is efficient, but stress concentrations and weld defects occur
Solution Approach 1:
The welding process incorporates real-time monitoring and control of weld bead geometry, ensuring the Z-shaped pattern is consistently formed with proper dimensions. Feedback mechanisms monitor weld pool temperature, deposition rate, and bead shape, automatically adjusting parameters to maintain manufacturing precision and prevent defects
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 Z-shaped weld pattern enhances the robustness of connections, reduces weld defects, and increases electrical conductivity, thereby improving the reliability and performance of battery assemblies in electrified vehicles.
Implementation Method 1
at least one first weld bead securing the busbar to the terminal
Data Source
AI summary
This disclosure relates to a battery assembly for an electrified vehicle and a corresponding method. An exemplary battery assembly includes a battery cell including a terminal, a busbar, and at least one first weld bead securing the busbar to the terminal. The at least one first weld bead is substantially Z-shaped.