Battery Contact Bonding Using Current-Generated Solder Heat

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Solution Overview

Problem

Existing methods for bonding components in high-voltage energy storage systems, such as those in electric vehicles, are complex and costly due to the need for oversized cables and sequential soldering, which complicates series production and accessibility to contact points.

Innovation Solution

A method that generates a flow of current through pre-positioned contact elements to bond them via thermal energy, using the energy storage unit itself or an external source to create a current path and apply heat for soldering, allowing for concurrent bonding of multiple contact points and reducing the need for sequential soldering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bonding methods such as soldering are used to reduce contact resistance, then contact resistance decreases and heat development is limited, but series production becomes complex and costly due to accessibility issues and sequential processing requirements

Engineering Contradiction:

Improvecontact resistanceVSAvoidproduction complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies self-service by using the electrical current that flows through the system during normal operation to generate the heat needed for bonding the contact points. The current path itself provides the thermal energy required to melt the solder material, eliminating the need for external heating equipment and complex sequential soldering processes. This allows bonding to occur automatically when current flows through the contact points.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements preliminary action by pre-positioning the solder material at the contact points before the bonding process. The contact elements are arranged and held in position with the solder material in place, ready for bonding. When current flows through the system, the pre-positioned solder material melts and bonds the contact points, eliminating the need for complex real-time positioning and bonding procedures.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If sequential soldering is used to bond contact points, then reliable bonds are achieved, but production time increases and manufacturing cost rises

Engineering Contradiction:

Improvebond reliabilityVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges multiple sequential soldering operations into a single concurrent bonding process. By using the current path to generate heat at all contact points simultaneously, all contact points are bonded at the same time rather than sequentially. This combines multiple bonding operations into one unified process, dramatically increasing production speed while maintaining bond reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies continuity of useful action by utilizing the continuous flow of current through the system to continuously generate heat at the contact points. Rather than interrupting current flow to apply external heat sources sequentially, the continuous current flow provides continuous heating, enabling simultaneous bonding of all contact points and eliminating production interruptions.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If oversized cables are used in high-voltage stores, then contact resistance is kept low and heat development is limited, but installation space, weight, and cost increase

Engineering Contradiction:

Improveheat managementVSAvoidcable weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent converts the harmful effect of contact resistance (which generates heat) into a beneficial effect. Instead of trying to eliminate contact resistance entirely by using oversized cables, the invention uses the heat generated by the contact resistance itself to bond the contact points. This converts the previously harmful thermal energy into a useful bonding agent, allowing the use of smaller, lighter cables while maintaining reliable electrical connections.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

This method simplifies and cost-reduces the bonding process by enabling smaller, more efficient components with lower contact resistances, saving space, weight, and installation effort, while ensuring reliable connections throughout the system's service life.

Implementation Method 1

generating a flow of current in the current path in order to bond the contact elements via the thermal energy produced in the current path

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20230378618A1Method for Contacting Components in Electric Systems in a Bonded Manner, Energy Storage Unit, and Use of the Energy of an Energy Storage Unit

Publication Date: 2023.11.23 BAYERISCHE MOTOREN WERKE AG

AI summary

A method for contacting components in electric systems in a bonded manner, including providing a plurality of components having contact elements for making electric contact, contacting the components via the contact elements in order to generate a current path, and generating a flow of current in the current path in order to bond the contact elements via the thermal energy produced in the current path.