Wire Bonding High-Voltage Energy Storage Module
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Solution Overview
Problem
Existing high-voltage energy storage modules for vehicles are costly and require significant maintenance, with rigid connections that are not flexible and prone to vibration, and lack efficient monitoring systems.
Innovation Solution
The use of wire bonding with bonding wires to connect electrochemical elements in a high-voltage energy storage module, allowing for automated production, reduced weight, and flexible connections, along with a circuit board for monitoring cell voltage and temperature, eliminating the need for additional welding materials and tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid cell connectors or cables are used to connect storage cells, then electrical connection is achieved, but the connection is heavy, inflexible, and susceptible to vibration damage
Solution Approach 1:
The patent replaces rigid mechanical connectors and cables with wire bonding technology, substituting a mechanical connection system with a metallurgical bonding system. The bonding wires are attached to the poles through wire bonding (micro-welding), where part of the bonding wire is melted by applying ultrasonic vibrations to create a metallurgical bond, eliminating the need for rigid mechanical components while reducing weight and improving flexibility.
Solution Approach 2:
The patent changes the physical state and properties of the connection medium from rigid solid connectors to thin, flexible bonding wires that can be melted and bonded. The bonding wires are relatively thin and bendable, allowing them to compensate for length extensions and resist vibration damage while maintaining electrical conductivity for high currents.
2Strength
If traditional welding or soldering methods are used to connect storage cells, then strong electrical connection is achieved, but additional welding material and tools are required, increasing cost and complexity
Solution Approach 1:
The patent extracts and eliminates the need for additional welding materials (such as solder or welding flux) and complex welding tools from the connection process. Wire bonding is performed by directly melting and bonding the bonding wire to the poles through ultrasonic vibrations, without requiring any additional welding material or solder, thereby simplifying the production process and reducing costs.
Solution Approach 2:
The bonding wire itself serves as both the connection medium and the bonding material. The wire bonding process uses the bonding wire's own material properties, melting part of it through ultrasonic vibrations to create the connection, eliminating the need for separate welding materials or additional tools.
3Adaptability or versatility
If a large number of thin bonding wires are used to conduct high current, then flexibility and vibration resistance are improved, but the complexity of ensuring adequate line cross section increases
Solution Approach 1:
The patent divides the electrical connection into multiple thin bonding wires arranged in parallel between the poles. Each bonding wire is relatively thin and bendable, and a large number of them are used together to conduct the main current (e.g., 200 A). This segmentation allows the connection to be flexible and resistant to vibration while collectively providing adequate line cross section for high current conduction.
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 production costs, minimizes maintenance, and provides a lightweight, flexible, and reliable high-voltage energy storage module with efficient monitoring capabilities, capable of handling high currents and compensating for length variations and vibrations.
Implementation Method 1
In order to produce the connection, part of the bonding wire is melted. This is done, for example, by applying ultrasonic vibrations to the bonding wire.
Data Source
AI summary
A high-voltage energy storage module for supplying a voltage, in particular to a motor vehicle, includes at least two storage cells and at least one electrically conductive connection between two poles of different storage cells. The individual connection consists of multiple adjacently arranged bonding wires, and each bonding wire is secured to the two poles by means of a wire bonding.