Energy Storage Device Assembly Weld Bonding
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Solution Overview
Problem
Conventional energy storage device assemblies face issues with durability and performance due to loose connections, complex bonding mechanisms, and imprecise fits, which can lead to dislodging, wear, and inefficient energy transfer between capacitor cells.
Innovation Solution
The solution involves a modular energy storage device assembly with weld bonds connecting adjacent electrodes in series, arcuate bus bars that partially surround electrodes, and a structural thermal bridge with recessed thermal plates to secure and thermally communicate with energy storage devices, reducing the need for high-resistance bus bars and enhancing thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional securing components are used to hold energy storage devices together, then the assembly structure is simple, but the connections are loose and can be dislodged by vibratory forces, reducing durability
Solution Approach 1:
The patent merges the mechanical securing function and electrical connection function into a single integrated component. The tab connects adjacent energy storage devices through a hole, providing both structural support and electrical conductivity, eliminating the need for separate securing components and adhesives while ensuring stable connections that resist vibratory forces
Solution Approach 2:
The tab serves multiple functions simultaneously: it acts as a structural support element, an electrical conductor, and a positioning feature. By making the tab multi-functional, the design achieves reliable connections without adding complexity to the assembly structure
2Reliability
If adhesive substances and thermal inserts are used between capacitor cells, then heat dissipation is improved and rotation/dislodging is reduced, but the bonding mechanisms become complex and performance is impaired
Solution Approach 1:
The patent removes adhesive substances and thermal inserts from the design, replacing them with a mechanical connection system using tabs. This extraction eliminates the complexity of bonding mechanisms while maintaining reliable thermal and electrical connections through the rigid tab structure
Solution Approach 2:
The patent replaces chemical bonding (adhesives) with a mechanical connection system. The tabs provide structural support and thermal management through direct mechanical contact and rigid mounting, eliminating the need for complex bonding mechanisms
3Reliability
If bus bars with circular ends are used to connect capacitor cells, then full surrounding connection is achieved, but precise machining is required, increasing manufacturing time and complexity
Solution Approach 1:
The patent segments the connection system into simple tab components with holes, replacing the complex circular bus bar design. This segmentation allows for easier manufacturing while maintaining reliable connections, as the tabs can be easily positioned and secured through the holes without requiring precise circular machining
4Strength
If radial weld or radial interference fit is used to attach terminals to cells, then attachment is achieved, but the geometries are complex and manufacturing processes become difficult
Solution Approach 1:
Instead of attaching terminals to the side of cells through complex radial welds or interference fits, the patent inverts the approach by having tabs pass through holes in the cells and connect adjacent devices. This simplifies the manufacturing process while maintaining strong attachment through direct penetration and mechanical engagement
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 configuration improves the durability and performance of energy storage devices by securely connecting electrodes in series, reducing manufacturing complexity, and enhancing thermal management, leading to more efficient energy transfer and longer device lifespan.
Implementation Method 1
a weld directly bonding adjacent first and second projecting electrodes of adjacent energy storage devices to one another in series
Implementation Method 2
a structural thermal bridge including at least one thermal plate configured to engage an end of at least a pair of the plurality of energy storage devices to physically secure the energy storage devices and thermally communicate heat therefrom
Data Source
AI summary
The present disclosure includes various assemblies to be used with one or more energy storage devices. In one embodiment, an energy storage device assembly can include a plurality of energy storage devices, and each of these energy storage devices can include a first projecting electrode and a second projecting electrode. The energy storage devices can be connected to each other through a weld, which can directly bond the adjacent first and second projecting electrodes of adjacent energy storage devices to one another. This configuration can allow each of the energy storage devices to be connected together in series.