Welded Electrode Assembly with Thermal Bridge
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Solution Overview
Problem
Conventional energy storage device assemblies face issues with durability and performance due to loose connections, high resistance bus bars, and complex manufacturing processes, which can lead to faulty and inconsistent performance under vibratory forces and thermal stress.
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 simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional securing components are used to hold energy storage devices together, then the assembly can be manufactured with simple components, but the securing components cannot withstand vibratory forces and lead to reduced durability
Solution Approach 1:
The patent combines multiple functions into the housing structure: mechanical securing, thermal management, and structural support are integrated into a single unified housing design, eliminating the need for separate complex securing components while improving durability
Solution Approach 2:
The housing is designed with modular segments that can be assembled together to secure energy storage devices, allowing the structure to withstand vibratory forces while maintaining manufacturing simplicity through standardized modular components
2Temperature
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 housing integrates thermal management functionality directly into its structure through integrated thermal pathways and heat dissipation features, eliminating the need for separate adhesive substances and thermal inserts while simplifying the overall bonding mechanism
Solution Approach 2:
The patent replaces complex chemical bonding mechanisms (adhesives) with mechanical securing features integrated into the housing structure, such as recesses, protrusions, and interlocking geometries that provide both structural support and thermal management
3Reliability
If bus bars with circular ends are used to connect capacitor cells, then full surrounding connection is achieved, but precise machining is required which increases manufacturing time
Solution Approach 1:
The bus bar connection geometry is designed with asymmetric features that provide reliable electrical connection without requiring precise circular machining, such as flat contact surfaces, elongated contact areas, or non-circular cross-sections that are easier to manufacture
Solution Approach 2:
The patent changes the geometric parameters of the bus bar ends from precise circular shapes to simpler geometries (such as rectangular, elliptical, or flat surfaces) that maintain connection reliability while significantly reducing machining time and complexity
4Strength
If radial weld or radial interference fit is used to attach terminal to cell, then connection is achieved, but complex geometries are required which add manufacturing difficulty
Solution Approach 1:
Instead of attaching the terminal to the cell end (radial approach), the patent inverts the attachment geometry to use axial or end-face welding/fitting methods, which simplify the manufacturing process while maintaining or improving attachment strength
Solution Approach 2:
The terminal attachment design is made universal by using standardized welding or fitting procedures that can be applied to various cell types without requiring complex custom geometries, improving ease of manufacture while maintaining strong connections
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 enhances the durability and performance of energy storage devices by securely connecting electrodes in series, reducing resistance, and improving thermal management, while allowing for modular scalability and customization.
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.