Energy Storage Module Assembly with Pre-compression and Reference Positioning
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Solution Overview
Problem
Existing methods for manufacturing electrical energy storage modules are inefficient, leading to increased bulk and manufacturing complexity, as they struggle to account for manufacturing tolerances and assembly variations, resulting in higher costs and discarded components.
Innovation Solution
The method involves using electrically insulating sleeves between adjacent assemblies and applying forces perpendicular to their longitudinal axes to press them together, with conductive bars connected by welding, ensuring precise positioning relative to external reference planes for consistent output terminal placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a holding member with openings larger than assembly dimensions is used to compensate for manufacturing tolerances, then assembly reliability is improved, but module size increases
Solution Approach 1:
The method applies forces perpendicular to the longitudinal axes of assemblies before final positioning to pre-compress assemblies against each other. This preliminary action eliminates the need for oversized holding member openings, as assemblies are already compressed to their tightest fit before being secured in the holding member.
Solution Approach 2:
The invention changes the physical state of assemblies by applying compressive forces that alter their dimensional parameters temporarily during assembly. This compression allows assemblies to fit more tightly together, reducing the clearance required in holding member openings while maintaining reliability.
2Manufacturing precision
If ossicles are positioned between covers of adjacent assemblies to hold them in position, then assembly positioning is improved, but device complexity increases due to difficult design requirements
Solution Approach 1:
The invention extracts the positioning function from complex ossicle components and transfers it to the holding member structure itself. The holding member incorporates positioning features directly into its body, eliminating the need for separate ossicle components and their complex design iterations.
Solution Approach 2:
The positioning function previously performed by separate ossicle components is merged into the holding member structure. The holding member now integrates both support and positioning functions, reducing the total number of components and simplifying the overall assembly process.
3Reliability
If bi-covers are used to electrically connect two adjacent assemblies, then electrical and thermal performance is improved, but manufacturing process complexity increases
Solution Approach 1:
The invention segments the connection function into separate components: the holding member provides mechanical support and positioning, while separate conductive bars provide electrical and thermal connections. This segmentation allows each component to be optimized independently and simplifies the manufacturing process compared to integrated bi-covers.
Solution Approach 2:
The holding member is designed with multi-functionality, serving both mechanical support/positioning and electrical connection purposes through integrated conductive elements. This universal approach eliminates the need for separate bi-cover components while maintaining electrical and thermal performance.
4Reliability
If assemblies are arranged with larger spacing to account for manufacturing tolerances, then assembly reliability is improved, but productivity decreases due to increased module bulk
Solution Approach 1:
The method applies compressive forces to assemblies before final positioning to pre-establish tight tolerances. This preliminary compression action allows assemblies to be placed closer together in the holding member, increasing the number of assemblies per module and improving manufacturing efficiency without sacrificing reliability.
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 minimizes module size, reduces manufacturing complexity, and maintains consistent output terminal positioning across identical modules, despite assembly variations, thereby enhancing manufacturing efficiency and reducing waste.
Implementation Method 1
the connection, in particular by welding, of the at least one bar on the assemblies
Data Source
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AI summary
The invention relates to a module including assemblies for storing electrical energy, and to a tool and a method for producing such a module, said method comprising the positioning of at least one electroconductive strip on the assemblies, the position of the at least one strip being pre-determined in relation to at least one reference plane. The invention also relates to a tool allowing the production of said module. Said tool comprises elements allowing the elements (capacitors) to be held against each other while the connection strips are welded to the elements.