Conductor Wire Surface Bonding for Energy Storage Cells

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing method of establishing electric contact between energy storage cells and conductor plates by running conductor wires through perforations is costly and inefficient.

Innovation Solution

Connecting conductor wires directly to the surface of the conductor plate structure facing the energy storage cells, eliminating the need to run wires through perforations, and using bonding methods like thermo-compression or wire bonding with conductive metals like aluminum or copper.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conductor wires are run through perforations on the side of the conductor plate structure, then electric contact is established, but manufacturing cost increases

Engineering Contradiction:

Improveelectric contactVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of running conductor wires through perforations from one side of the conductor plate to the other, the invention inverts the approach by making contact only on the surface facing the energy storage cell. The conductor wire is attached to the cell and contacts the conductor plate surface directly, eliminating the need for through-perforations and reducing manufacturing complexity while maintaining electrical connectivity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention extracts the unnecessary portion of the conventional approach by removing the requirement for wires to pass through the entire conductor plate structure. Only the essential contact function is retained - the wire contacts the conductor plate surface where it is needed, without requiring penetration through the plate, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If conductor wires are run through perforations in the conductor plate structure, then electrical connection is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention inverts the conventional wiring approach by eliminating through-perforations entirely. Instead of routing wires through the conductor plate from one side to the other, the wires are attached to energy storage cells and make contact with the conductor plate surface directly, significantly reducing manufacturing complexity while maintaining reliable electrical connection.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If conductor wires are attached to the surface of the conductor plate structure, then manufacturing cost is reduced, but contact reliability must be maintained

Engineering Contradiction:

Improvemanufacturing costVSAvoidcontact reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The conductor wires are preliminarily attached to the energy storage cells before assembly, with the attachment points positioned to ensure direct contact with the conductor plate surface. This preliminary positioning ensures that when the module is assembled, reliable electrical contact is achieved without requiring complex through-plate routing, thus maintaining contact reliability while simplifying manufacturing.

Inventive Principle:

Principle #10Preliminary action

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 approach reduces manufacturing costs by avoiding expensive perforation processes and ensures reliable, efficient electrical contact for energy storage devices, such as those used in motor vehicles.

Implementation Method 1

using bonding methods like thermo-compression or wire bonding with conductive metals like aluminum or copper

Methodology Applied

Scientific EffectThermo-compression bonding:

Implementation Method 2

using bonding methods like thermo-compression or wire bonding with conductive metals like aluminum or copper

Methodology Applied

Scientific EffectWire bonding:

Implementation Method 3

Connecting conductor wires directly to the surface of the conductor plate structure facing the energy storage cells, eliminates the need to run wires through perforations

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10593923B2Method for establishing electric contact between an energy storage cell and a conductor plate structure

Publication Date: 2020.03.17 AUDI AG

AI summary

A method for establishing an electric contact between an electric energy storage cell and an electrically conductive conductor plate structure, The electric energy storage cell is contacted via at least one electrically conductive conductor wire with the conductor plate structure. At least one electrically conductive conductor wire is connected to create electric contact of the electric energy storage cell with the electrically conductive conductor plate structure at a surface of the electrically conductive conductor plate structure facing an electrically conductive storage cell.