Energy Storage Cell Self-Welding for Automated Electrical Connection
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Solution Overview
Problem
The labor-intensive process of welding hundreds of energy storage cells in high-voltage stores or traction batteries requires significant effort and accessibility, leading to high production costs.
Innovation Solution
A method where the energy storage cells act as a 'bolt' to weld themselves to contact elements using their internal energy, generating a welding connection through an electrical circuit that produces a current flow and temperature increase, eliminating the need for external energy sources and allowing for automatic welding without subsequent accessibility requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding methods are used to electrically connect energy storage cells, then reliable electrical connections are achieved, but the production process becomes labor-intensive and requires significant accessibility
Solution Approach 1:
The energy storage cell itself serves as the energy source for welding its own connection elements. The cell's stored energy is utilized to create the welding connection at the contact point between its connection element and the contact plate, eliminating the need for external welding equipment and operators.
Solution Approach 2:
The patent replaces traditional mechanical welding systems (external welders, operators, welding equipment) with an electrical self-welding system. The mechanical act of welding is substituted by an electrical process where current from the cell generates heat to fuse the connection elements.
2Ease of manufacture
If external welding equipment is used to connect energy storage cells, then welding connections are achieved, but external energy sources and equipment are required
Solution Approach 1:
The energy storage cell performs multiple functions: it stores energy for operation and simultaneously serves as the energy source for creating its own electrical connections. The connection elements are designed to function both as electrical conductors and as workpieces to be welded.
Solution Approach 2:
The patent extracts the welding energy source from external equipment and relocates it to the energy storage cell itself. By taking out the external welder and replacing it with the cell's own stored energy, the system eliminates complex external welding equipment.
3Reliability
If hundreds of energy storage cells are welded in a high-voltage store, then complete electrical interconnection is achieved, but production time and costs increase significantly
Solution Approach 1:
Each energy storage cell autonomously creates its own welding connections without requiring external welding operations. This self-welding capability allows for parallel processing where multiple cells can be connected simultaneously without sequential welding operations.
Solution Approach 2:
The connection elements are pre-configured with connection poles and contact surfaces that are ready for welding. The cells are positioned and pre-contacted before the welding process, so that when energy is supplied, the welding occurs immediately at the predetermined contact points without requiring complex positioning or alignment during welding.
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 reduces production costs and effort by utilizing the energy storage cells' internal energy for welding, enabling efficient and automated connection of multiple cells without the need for external energy or extensive accessibility during the welding process.
Implementation Method 1
the current flow generates a temperature increase at the contact points in such a way that welding takes place
Implementation Method 2
An arc is preferably ignited between the first connection pole and the first contact element, the arc melting the first connection pole and/or the first contact element, as a result of which a welding pool is created
Data Source
AI summary
A method for electrically connecting an energy storage cell includes providing at least one electrical energy storage cell, comprising a first connecting pole, arranging the first connecting pole and a first contact element to each other for forming a first contact point and closing an electrical circuit over the at least one energy storage cell and utilizing the electrical energy stored in the energy storage cell for producing a welding connection at the first contact point.