BATTERY CONNECTION ADAPTER THAT ALLOWS DISASSEMBLY

Abstract

This invention relates to an adapter structure that enables the terminal connections of cylindrical batteries, and especially lithium-ion cells (e.g., 18650, 21700, 26650, etc., with standard dimensions) used in electrical energy storage systems, to be mechanically detachable, electrically reliable, and standardized in terms of manufacturing processes. The subject of the invention is the integration of standard cylindrical cell structures (1) into the system via an adapter (2) which is a connecting element that can be mounted both by welding and in a detachable manner in energy storage systems. This structure eliminates the mechanical and electrical risks associated with making busbar (9) connections directly to the cell terminal by welding as in the previous technique.

Description

1 TARIFF BATTERY CONNECTION ADAPTER THAT ALLOWS DISASSEMBLY This invention develops cylindrical batteries used in electrical energy storage systems. and especially lithium-ion cells (e.g., 18650, 21700, 26650 etc. dimensional) (having standards) terminal connections, mechanically detachable, electrically to make it reliable and standardizable in terms of production processes It relates to an adapter structure that provides 10. The adapter described in this invention can be connected to the cell terminal by welding and by forming a bolt / nut interface on its opposite surface, it carries electrical current. It is possible to make connections that can be resolved with elements (e.g., busbars). This structure is reliable in terms of both electrical and mechanical performance. Risks in terms of maintenance and disassembly have been minimized, and in terms of production, it is 15. It offers a connection solution suitable for automation. Terminal of cylindrical cells currently used in energy storage systems connection; by resistance welding, ultrasonic welding or laser welding methods These methods are applied directly to conductive busbar structures. These methods are permanent and non-removable. It forms combinations and has the following technical limitations: 20 • Non-removable connections: Requiring repair, maintenance, or cell replacement. In these cases, the welded connection needs to be physically broken. This process damages both the cell terminal and the busbar element. There is a risk of fire, short circuit, etc., during such interventions. This creates serious safety risks such as thermal runaway. 25 • Uncontrollability of Joint Quality: Weld quality; surface cleanliness, welding numerous factors such as the atmospheric conditions of the environment, source current, and coupling force It depends on the variable. These parameters need to be controlled, especially... each component is checked for performance during production. It is strong. Electrical contact resistance and mechanical strength are 30. They cannot be evaluated, resulting in security vulnerabilities and quality differences. It consists of. 2 • Lack of Geometric Flexibility and Automation Challenges: The Cell Configurations and busbar designs vary in each application. demonstrating the technical aspects of establishing a consistent production process and resource automation. and makes it economically inefficient. • For these reasons, current connection techniques; quality assurance in the production process 5 which cannot be provided, and which endangers life and property safety during maintenance. These methods are limited due to their low scalability. The adapter structure described in this invention aims to solve the technical problems mentioned above. It is designed for this purpose. The adapter consists of two functional surfaces: 1. Cell connection surface: Adapter, resistor, laser or standard cell terminal. It can be bonded using one of the ultrasonic welding methods. This surface, It provides a permanent connection between the adapter and the cell. 2. Bolted connection surface: On the opposite side of the adapter, a conductive busbar or similar connection point. A threaded (nut type) structure suitable for mounting the current-carrying structure is available. This 15 An electrical connection is established by mechanically tightening the material over the surface. 3.1. Innovative Technical Specifications of the Adapter: • Standardized Geometry: Adapter dimensions, cell type (18650, 21700, Defined by (e.g., 26650). A fixed adapter profile for each cell type. By using, fixed source parameters for the cell-adapter junction are maintained. Welding jigs and a constant process flow can be ensured. This structure enables production. This makes it possible to automate the process. 25 • Predictable and Controllable Sourcing Area: The sourcing process is no longer variable. Instead of a busbar with a specific geometry, a fixed adapter is used between the cell. This is implemented. Thus, the welding process is measurable in terms of quality control. It can be linked to parameters (e.g., source voltage, duration, surface temperature) and These parameters become monitorable through automation. 30 • Detachable Electrical Connection: Permanent connection source between cell and adapter. This is ensured by a bolted connection between the adapter and the busbar. Thus, maintenance is easy on the cell. 3 during replacement or revision processes, only the bolt connection It is sufficient to dissolve it. During this process, neither the cell nor the bar surface is damaged. Assembly / disassembly can be performed without prior notification. • Checking Electrical Contact Resistance: In bolted connections, the contact resistance is 5 It is directly related to the tightening torque. Therefore, the connection between the adapter and the busbar... The surface contact pressure created is a controllable engineering process. It is a parameter. Thus, the electrical characteristics of the connection points. (Resistivity, contact stability, etc.) can be calculated, tested, and repeated. becomes. 10 • Calculability of Mechanical Strength: Mechanical load bearing capacity of bolted connections. classic based on capacity, adapter geometry and bolt / nut characteristics. It can be calculated using connection engineering methods. Thus, the impact, Even under external influences such as vibration or thermal expansion, the safety of the connection is 15 It is possible to guarantee this. • This discovery is then explained with illustrations and examples. Reference List: 20 1- Cell (Battery) 2- Adapter 3- Weld Surface 4- Bolt Interface (Nut Hole) 5- Tightening Torque Control and Busbar Electrical Contact Surface 25 6- Source Regions 7- Standard Geometric Connection Profile 8- Welding Automation Guide Flange 9- Busbar (Current Carrying Strip / Plate) 10- Cell (Battery) Positive and Negative Terminals 30 4 Explanation of the Figures: Figure-1 Design of the adapter subject to the invention (a) front isometric view, (b) rear isometric (c) is the view and (c) is the cross-sectional view. Figure 2 Subject of the invention Adapter and cell assembly method (a) pre-negative cell 5 (b) Isometric view from the terminal side and (b) from the posterior-positive cell terminal side It is an isometric view. Figure 3 shows the adapter, the subject of the invention, mounted on the cell terminal. It is the appearance. Figure 4 shows the cell group with the adapter mounted on it and the adapters connected to busbar 10. assembly method view. Figure 5. The subject of the invention is a busbar assembly with adapter cells already installed. It is the appearance of a group of cells. DETAILED DESCRIPTION OF THE INVENTION: The subject of the invention is the adapter (2) in the form of a standard cylindrical structure. cells (1), which are both source-fixed and in energy storage systems 20 via adapter (2) which is a detachable mounting element This structure includes the integration of the busbar (9) connections into the system. as in the previous technique, by welding directly to the cell (1) terminal It eliminates the mechanical and electrical risks it introduces. The adapter body (2) passes directly through the source surface (3) to the cell (1) 25 to terminal (10) by one of the laser, resistance or ultrasonic welding methods They are permanently fixed by applying welding to the (6) regions. Welding The process is a welding automation guide suitable for automation on the production line. aligned with the flange (8) and weld quality, surface cleanliness and welding current such as It is made possible to keep the resources under control with parameters. In this way, the resource The combination becomes repeatable, predictable, and controllable. 30 The bolted interface (4) located on the top of the adapter (2) transmits current like the busbar (9). This enables a carrier element to be detachably connected to the adapter (2). The connection is made via a bolt tightened to a specific torque. Tightening torque The control surface (5) measures the pressure of the applied torque on the adapter-bus junction surface. It determines. This contact enables current transmission through the electrical contact surface (5) and It operates with low contact resistance. The adapter has a standard geometric connection profile (7). Thanks to this feature, 5 Pre-defined according to cell (battery) (1) sizes such as 18650, 21700, 26650 and It is possible to work with automated source parameters. The dimensional stability of the adapter (2) is ensured by both the welding process and the bolted connection. It ensures standardization during production. In the previous technique, since the bar (9) was welded directly to the cell terminal: 10 • When cell replacement was necessary, the connection could only be severed through physical destruction. • The cell terminal and bar could be damaged, • Welding quality, against environmental and process variables during joining. It showed high precision. • The monitoring and automation processes were complex. 15 With this invention, the busbar (9) is now bolted to the adapter (2) instead of the cell terminal. It is connected to the interface (4). This connection is easily made by simply unscrewing the bolt. It can be disassembled. This allows for maintenance, cell replacement, fault detection, or reassembly. Configuration operations can be performed safely and without damage. To the cell (1) or risk of physical harm to the bar (9) is eliminated, occupational health and safety 20 This provides a significant advantage. In conclusion, thanks to this structure: • A permanent, robust and controllable weld is required between the cell and the adapter. connection, • A secure, detachable and standardized 25mm cable is provided between the adapter and the busbar. A bolted connection is provided. • All systems comply with engineering calculations and have repeatable production. It is supported by scenarios. The adapter (2) is a relatively larger diameter 30 at the base of a cylindrical body. It is designed in the form of a flange positioning. 6 1. Automation and Quality Assurance of Standardized Adapter Design Its effect The subject of the invention is the adapter (2), cylindrical adapter used in energy storage systems. Terminals of lithium-ion cells (e.g., 18650, 21700, 26650 standards) by offering standardized dimensions and geometry in its connections, source 5 It provides full compatibility with the automation of processes. Welded joints (resistance, ultrasonic, laser welding) variations observed in quality parameters To minimize the dimensions and mounting positions of the adapter (2) on the production line. It can be integrated into automation systems. This allows for resource... 10 of its parameters (welding current, welding time, pressure, atmospheric conditions) Repeatability and controllability are increased. Thus, electrical... The bond strength and electrical resistance values ​​of the connection are statistically analyzed. process control (SPC) methods based on standard deviation and mean values Quality assurance is ensured through monitoring. 2. Mechanical and Electrical Performance Advantages of Bolted Connection Systems 15 The connection between the cell terminal (10) and the busbar (9) via the adapter (2) Securing it with bolts allows for direct control of the connection force. The bolt tightening torque provides the normal force between the mating surfaces (5). This force determines and is the fundamental determinant of electrical contact resistance. This is the case in engineering calculations. The tightening torque for bolts and nuts is 20. material properties, friction coefficients and contact surface geometry are taken into consideration By taking this approach, the durability of the electrical connection can be optimized. This method, Microscopic cracks and oxidation that can occur at weld joints compared to its problems, it offers more stable and predictable electrical performance. It provides. 25 3. Occupational Health and Safety and Operational Efficiency Cell terminal and busbar during disconnection of source connections. The risks of mechanical deformation on their surfaces are minimized with an adapter bolt system. It has been completely eliminated. This situation affects field maintenance and damage. In these cases, cell (1) exchange is fast, safe and harmless 30 This enables the implementation of these measures. The risk of workplace accidents is minimized. Operation time and costs are reduced. Additionally, the disconnection and reconnection of connections are minimized. Mechanical fatigue and material damage occur even when the frequency of reconnection increases. The risks are reduced. 7 4. Measurability and Traceability of Electrical and Mechanical Health The tightening torque of a bolted connection system according to engineering standards. measurement of the bond strength (by torque-moment calculations) and contact This makes it possible to directly monitor its resistance (through electrical measurements). thanks to the assembly quality, calibrated torque wrenches and electrical test 5 This can be continuously verified with the devices. As a result, energy storage The long-term reliability of the systems is increasing and maintenance periods are becoming more efficient. It can be planned. 5. Material Compatibility and System Flexibility in Adapter Design The design of the adapter (2) accommodates battery cells with different chemical structures and terminal 10 optimized to ensure chemical and mechanical compatibility with materials The adapter (2) material has been made in terms of contact resistance and corrosion resistance. By using selected alloys, the electrical connection is resistant to environmental conditions. Its durability has been increased. In addition, the adapters (2) are designed according to the cell sizes. Designed with parametrically variable dimensions, different battery module 15 This allows them to easily adapt to various configurations. 6. Future Development Potential and Smart Monitoring Systems The adapter (2) developed within the scope of the invention will be integrated in the later stages. with high-capacity electronic sensors (for example, contact pressure sensors, (temperature sensors) can be installed. In this way, the bolted connection can be monitored in real time. Smart battery management systems for monitoring and energy storage systems. (BMS) compatible data collection will become possible. This will improve security, It offers significant advantages in terms of performance and service life. With the features listed above, the subject of the invention is the adapter (2) and the adapter (2) The method of application is new. 25

Claims

8 REQUESTS 1- The subject of the invention is energy storage cells in standard cylindrical form (1). in their systems both fixed by welding and demountable. It is a connecting element and its feature is; it has a weld surface (3), bolted interface 5 (nut socket) (4), tightening torque control and busbar electrical contact surface (5), welding regions (6), standard geometric connection profile (7), welding automation guide flange (8) is characterized by being. 2- According to Claim-1, it is an invention and its feature is; directly from the source surface (3) 10 from laser, resistive or ultrasonic welding methods to the (1) terminal of the cell (10) permanent fixation by applying welding process to one of the source regions (6) The adapter is characterized by (2). 3- An invention according to claim 1 or 2, and its feature is; a current carrying device such as a busbar (9) 15 It has a bolted interface (4) that allows the element to be attached in a detachable manner. It is the adapter (2). 25

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