Pre-mounted Connection Elements for Battery Pack Assembly
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Solution Overview
Problem
The existing methods for producing electrical energy stores for motor vehicles, such as battery packs, are time-consuming and costly due to the complexity of connecting terminals to current collecting elements through wire bonding, which requires precise alignment and detection of suitable connection points.
Innovation Solution
The solution involves pre-mounting connection elements on a retaining element independently of the storage cells and current collecting elements, allowing for simplified and cost-effective electrical and mechanical connection by welding, thereby avoiding the need for precise alignment and wire bonding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonding is used to connect terminals to current collecting elements, then electrical connection is achieved, but production time increases and cost increases
Solution Approach 1:
The patent extracts the connection element from the terminal structure and integrates it into the retaining element. This separation allows the connection element to be pre-mounted on the retaining element before the battery pack is assembled, eliminating the need for time-consuming wire bonding operations during final assembly while maintaining reliable electrical connections.
Solution Approach 2:
The connection elements are pre-mounted on the retaining element in advance, before the battery pack assembly process begins. This preliminary action enables subsequent welding operations to be performed more efficiently and reduces the overall production time by avoiding complex alignment and wire bonding steps during final assembly.
2Reliability
If wire bonding is used to connect terminals to current collecting elements, then electrical connection is achieved, but production cost increases
Solution Approach 1:
The connection element is extracted from the terminal and integrated into the retaining element, allowing for simpler and more cost-effective welding operations instead of expensive wire bonding processes. This structural modification reduces material costs and manufacturing complexity.
Solution Approach 2:
The patent employs a simpler connection structure using welding instead of wire bonding, which uses less expensive materials and processes. The connection element integrated into the retaining element provides a cost-effective alternative to traditional wire bonding methods.
3Manufacturing precision
If precise alignment and detection of suitable connection points is performed, then connection quality is improved, but production time increases
Solution Approach 1:
The connection elements are pre-mounted on the retaining element with proper alignment before battery pack assembly. This preliminary positioning eliminates the need for complex alignment and detection operations during final assembly, maintaining manufacturing precision while significantly improving production speed.
Solution Approach 2:
By extracting the connection element from the terminal structure and pre-mounting it on the retaining element, the patent eliminates the need for precise alignment and detection of connection points during battery pack assembly, thereby improving productivity without sacrificing connection quality.
4Reliability
If wire bonding process is used, then electrical connection is achieved, but quality issues such as particle contamination and alignment errors occur
Solution Approach 1:
The patent replaces the wire bonding process with a welding-based connection system. The connection element integrated into the retaining element is welded to the terminal, eliminating the harmful effects of wire bonding such as particle contamination and alignment errors while maintaining reliable electrical connections.
Solution Approach 2:
By extracting the connection function from the terminal and integrating it into the retaining element with pre-mounted connection elements, the patent eliminates the wire bonding process entirely, thereby removing the source of particle contamination and alignment errors associated with that process.
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 enables the production of electrical energy stores in a time-saving and cost-effective manner by simplifying the connection process and reducing the risk of quality issues associated with wire bonding, such as particle contamination and alignment errors.
Implementation Method 1
The connection element (7) is electrically connected to the terminal (4) of the storage cell (2) and to the current collecting element (6) by welding
Data Source
AI summary
An electrical energy store for a motor vehicle includes storage cells, a retaining element which is supported on the storage cells and by way of which the storage cells are fixed relative to one another, and a current collecting element common to the storage cells and held on the retaining element, to which current collecting element a terminal of each storage cell is electrically connected. The terminal of each storage cell is electrically connected to the current collecting element via a connection element, which is pre-mounted on the retaining element at a mounting point independently of the current collecting element and independently of the storage cells.