Capacitor energy storage seam welding techniques

What is capacitor discharge welding?

Capacitive discharge welding, particularly for large-scale systems, is typically done using film-type capacitors. These capacitors store energy along alternating plates separated by a dielectric film. Charge is stored statically along the lengths of the plates. The basic configuration of the film capacitor is provided in Figure 1.

Do electrolytic capacitors yield identical weld performance results?

The results presented here indicate that electrolytic capacitors, configured to provide similar charge voltage and energy storage, can yield identical weld performance results. Process, mechanical strength, and metallographic results are all identical for the two capacitor arrangements.

How do you find the optimal weld seam?

The optimal geometry of the weld seam for the used test samples is given by the edges transversely relative to the longitudinal direction of the overlap . The optimal weld seam can be realized by laser beam welding resulting in relatively low electrical contact resistances.

How to choose the best weld seam for ultrasonic welding?

The way the weld spots were arranged is the best approach of the optimal weld seam with the lowest electrical contact resistances. For ultrasonic welding, four sonotrodes with different dimensions were used. In Fig. 14 each welding technique has its own abscissa, because the welded areas depend on the joining technique.

Are electrolytic capacitors a viable alternative for large capacity CD welding systems?

Electrolytic capacitors (E-caps) offer a potential alternative for large capacity CD welding systems. E-caps incorporate an electrolyte impregnated into a separator. The separator is then sandwiched between anodic and cathodic foils. A dielectric is also used to prevent direct contact of the foils with the electrolyte.

How can ceramic capacitors be improved?

By optimizing their electrode structures or manufacturing processes, researchers aim to enhance the breakdown strength, dielectric stability, and energy density of ceramic capacitors, further expanding their capabilities and applications .