WO2009121614A1 - Improvements in or relating to joining copper and nickel containing metals - Google Patents
Improvements in or relating to joining copper and nickel containing metals Download PDFInfo
- Publication number
- WO2009121614A1 WO2009121614A1 PCT/EP2009/002457 EP2009002457W WO2009121614A1 WO 2009121614 A1 WO2009121614 A1 WO 2009121614A1 EP 2009002457 W EP2009002457 W EP 2009002457W WO 2009121614 A1 WO2009121614 A1 WO 2009121614A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- nickel
- copper
- nickel containing
- containing metal
- strip
- Prior art date
Links
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 title claims abstract description 97
- 229910052759 nickel Inorganic materials 0.000 title claims abstract description 48
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 39
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 39
- 239000010949 copper Substances 0.000 title claims abstract description 39
- 239000002184 metal Substances 0.000 title claims abstract description 31
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 31
- 150000002739 metals Chemical class 0.000 title abstract description 11
- 238000005304 joining Methods 0.000 title description 6
- 238000003466 welding Methods 0.000 claims abstract description 23
- 238000000034 method Methods 0.000 description 5
- 229910000990 Ni alloy Inorganic materials 0.000 description 4
- 238000009423 ventilation Methods 0.000 description 4
- 238000004146 energy storage Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 241000156302 Porcine hemagglutinating encephalomyelitis virus Species 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 239000008267 milk Substances 0.000 description 2
- 210000004080 milk Anatomy 0.000 description 2
- 235000013336 milk Nutrition 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
- H01M50/514—Methods for interconnecting adjacent batteries or cells
- H01M50/516—Methods for interconnecting adjacent batteries or cells by welding, soldering or brazing
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
- H01M50/503—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the shape of the interconnectors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
- H01M50/521—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the material
- H01M50/522—Inorganic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/36—Electric or electronic devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/12—Copper or alloys thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
- B23K2103/26—Alloys of Nickel and Cobalt and Chromium
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- the present invention relates to improvements in or relating to the joining of metals and in particular to the joining of copper to other metals.
- Copper is an important metal and finds widespread use due to its high thermal conductivity and high electrical conductivity.
- it cannot be welded to the other metals by traditional welding techniques as the copper will melt at a temperature below that at which the other metal can be welded.
- This can present difficulties in, for example, the production of battery systems where it is desirable to provide electrical conductivity between a plurality of battery cells in multi-cell battery systems such as those described in our co-filed patent application reference PAAJBA779.
- cell refers to an individual battery; the term “module” refers to several cells mounted together to provide a power generation unit and the term “system” refers to several modules linked together as the overall power generation unit.
- module refers to several cells mounted together to provide a power generation unit and the term “system” refers to several modules linked together as the overall power generation unit.
- system refers to several modules linked together as the overall power generation unit.
- voltage can be built by connecting cells in series whereas capacity (the amount of energy storage) can be built by connecting cells in parallel.
- the present invention provides a novel method for joining copper to nickel and nickel containing metals. It has been proposed that nickel may be joined to copper by laser welding. This however is an expensive technique requiring sophisticated laser equipment. Furthermore, the welds produced by laser welding have been found to be of variable strength and inconsistent electrical resistance rendering them unsuitable for use in electrical applications.
- ultrasonic welding provides an effective bond between copper and nickel containing metals and that the bond point has consistent strength and desirable low electrical resistance.
- the present invention therefore provides the use of ultrasonic welding to join copper to a nickel or nickel containing metal.
- the invention further provides an article comprising a copper element joined to a nickel or nickel containing metal element by ultrasonic welding.
- the invention is particularly useful in battery systems such as those described in co-filed patent application reference PAAJBA779.
- a series of battery cells are mounted in a module and a series of modules are connected together to provide a battery system.
- copper strip cannot be spot welded to the terminals of the cells. It is therefore preferred to employ a nickel or nickel containing material to connect to the terminal of the cells because this is susceptible to spot welding.
- a nickel or nickel containing metal strip is therefore employed to establish the connectivity between the copper conductor and the positive terminal of the cell. It is however then necessary to join the nickel or nickel containing metal strip to the copper in an effective manner that imparts low electrical resistance to the join. Ultrasonic welding has been found particularly useful in making such a join.
- Ultrasonic welding of other materials is well known.
- a nickel or nickel containing metal element is placed on the copper element between the anvil and the sonitrode of the ultrasonic welding system.
- the sonitrode is then forced downwards onto the area where the join is to be effected to subject a pneumatic squeeze to the two metals.
- the ultrasonic radiation is then applied and the optimum frequency that should be applied and the power duration depends upon the thickness of the copper element and the nature and thickness of the nickel or nickel containing metal element.
- the ultrasonic welding is used to produce connectors for multi-cell battery systems
- the copper sheet may be up to 1 millimeter thick and the nickel or nickel containing metal strip may also be up to 1 millimeter thick an effective weld can be produced in about one quarter of a second.
- the present invention provides a connector plate for use in a battery module comprising a copper plate provided with a series of holes positioned to correspond to the upper terminals of the cells within the battery module provided with a nickel or nickel containing metal connector strip bridging the holes, said strip being weldable to the upper terminals of the cells to establish electrical contact with the cell wherein the copper plate and the nickel or nickel containing metal strip are joined by ultrasonic welding.
- the nickel or nickel containing metal strip does not totally cover the holes in the copper plate to provide ventilation channels which can allow the flow of a cooling fluid through a battery module.
- the battery systems which employ connector plates according to the present invention can have varying power outputs . If the battery systems are used to drive vehicles different power outputs are required to drive light vehicles such as golf carts, milk floats and light automobiles than are required to drive heavy automobiles and heavy goods vehicles. Furthermore, different power outputs may be required if the battery system is to be used as a power supply component in a hybrid vehicle in which the battery system can be charged when the vehicle is operating under another power source than if the battery system is to be the sole source of power. In addition the need for ventilation can depend upon the power output required; low power full electric vehicles such as golf carts, milk floats and light vehicles may not require ventilation. Higher power hybrid vehicles or plug in hybrid vehicles where cooling (ventilation) holes and fluid flow are important.
- the power requirements are given what are known as "C” ratings. If the battery has a capacity of 40 KWh and it is powering a motor capable of 40 KW the application rating for power draw is 1C. If it were an 80 KWh battery for the same application the power draw would be C/2. If a 20 KWh battery was powering a motor capable of 40 KW the application rating would be 2C.
- high power electric vehicles such as hybrid vehicles (HEV) have a rating of about 3OC.
- Plug in hybrid vehicles (PHEV) have a rating of from 5C to 10C whereas electric vehicles (EV) typically have a rating from 1C to 5C more typically from 1C to 2C.
- a battery system employing the present invention has the benefit of flexibility concerning the number, capacity and size of cells that can be employed in a module and the number of modules that can be employed.
- modules or batches of modules may be located at different positions within the vehicle and they may be connected by wiring to secure the desired output of the entire battery system. In this way space can be saved within the vehicle structure.
- modules or batches of modules may be mounted on various structural components of the vehicle such as frame rails and pillars, around a drive shaft and other similar positions.
- the battery system is provided in a box preferably of glass fibre reinforced plastic to provide the necessary strength and insulation and can withstand the temperatures which may be generated by the operation of the battery system which can reach 160 c C.
- the present invention provides ultrasonic welding as an effective method of joining copper and nickel containing metals without having to create a heat based fusion weld.
- Ultrasonic welding creates an alloyed mix of the two materials where the weld is made.
- An added benefit of the present invention is that no third party binding medium such as solder is needed to effect the joint and the ultrasonic method of creating this junction provides a join of low resistance and high quality.
- Figure 1 shows a copper connector plate overlaid with strips of nickel alloy ready for ultrasonic welding.
- Figure 2 shows an ultrasonic weld being performed on the plate shown in Figure 1 at one of the locations where a weld is required.
- Figure 3 shows the copper connector plate shown in Figure 1 with the nickel alloy strips welded to the plate in several positions.
- Figure 1 shows a copper plate (1) provided with holes (2) overlaid with strips of nickel (3) and placed below the anvil (4) of an ultrasonic welding machine.
- the sonitrode (5) of the ultrasonic welding machine is positioned to deliver the ultrasound radiation to the location (6) where the weld is to be performed.
- Figure 2 shows 4 locations (7) where welds have been performed and a weld being performed at location (6).
- Figure 3 shows the final welded connector plate with the nickel strips (3) welded to the copper connector plate a locations (4) between the holes provided in the plate to correspond to the position of the terminals of the cells within a battery module.
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Connection Of Batteries Or Terminals (AREA)
Abstract
Copper and Nickel containing metals are joined together by ultrasonic welding particularly to provide connectors for use in multi cell battery systems where the nickel containing metal is required for spot welding to the cell terminals and copper is required to provide the overall conductivity of the connector. The welds are of high purity, reliable strength and constant low electrical resistance.
Description
IMPROVEMENTS IN OR RELATING TO JOINING COPPER AND NICKEL
CONTAINING METALS
The present invention relates to improvements in or relating to the joining of metals and in particular to the joining of copper to other metals. Copper is an important metal and finds widespread use due to its high thermal conductivity and high electrical conductivity. However because of its low melting point relative to other metals it cannot be welded to the other metals by traditional welding techniques as the copper will melt at a temperature below that at which the other metal can be welded. This can present difficulties in, for example, the production of battery systems where it is desirable to provide electrical conductivity between a plurality of battery cells in multi-cell battery systems such as those described in our co-filed patent application reference PAAJBA779.
It is therefore necessary to use another metal such as nickel or a nickel alloy to form the contact with the terminal of the battery cell.
However, within such a system it is highly desirable to optimize the use of the high electrical conductivity of copper perhaps for the flow of electricity from one module of cells to another and it is therefore necessary to join the nickel or nickel alloy to the copper. The use of copper can also have the additional benefits that it acts as a heat sink to dissipate heat generated by the battery system.
Although the invention has general applicability it will be described in relation to the provision of electrical conductivity in battery systems. Within this application the term
"cell" refers to an individual battery; the term "module" refers to several cells mounted together to provide a power generation unit and the term "system" refers to several modules linked together as the overall power generation unit. In order to generate sufficient power for a sufficient period of time several modules of cells may be assembled. For example voltage can be built by connecting cells in series whereas capacity (the amount of energy storage) can be built by connecting cells in parallel.
By way of example if a battery system is to be assembled from cells of voltage 3.2 volts 10 cells may be connected in series to provide a module of 32 volts. If the cells also
have a capacity of 1.6 Ah then connecting 10 cells in parallel will provide a capacity of 16 Ah. The energy storage is then the product of the voltage and the ampage. If again for example, an energy storage of about 45 kilo watt hours is required a system comprising 106 cells in parallel in each module and 84 modules in series may be employed. In this way if each cell is 3.2 volts and 1.6 Ah the system provides 106 x 1.6 Ah = 169.6 Ah and 84 x 3.2 volts = 268.8 volts. The capacity which is the product of the voltage and the ampage is 45588 watt hours or 45.588 kilo watt hours.
The present invention provides a novel method for joining copper to nickel and nickel containing metals. It has been proposed that nickel may be joined to copper by laser welding. This however is an expensive technique requiring sophisticated laser equipment. Furthermore, the welds produced by laser welding have been found to be of variable strength and inconsistent electrical resistance rendering them unsuitable for use in electrical applications.
We have now found that ultrasonic welding provides an effective bond between copper and nickel containing metals and that the bond point has consistent strength and desirable low electrical resistance.
The present invention therefore provides the use of ultrasonic welding to join copper to a nickel or nickel containing metal.
The invention further provides an article comprising a copper element joined to a nickel or nickel containing metal element by ultrasonic welding.
The invention is particularly useful in battery systems such as those described in co-filed patent application reference PAAJBA779. In this application a series of battery cells are mounted in a module and a series of modules are connected together to provide a battery system. Here it is necessary to provide the connection between the cells by spot welding a connector to the positive terminal of the cells and to provide connectivity between the modules. In view of its high electrical conductivity and low resistance it is desirable to optimize the use of copper in these connection systems. However because of its low melting point copper strip cannot be spot welded to the terminals of the cells. It
is therefore preferred to employ a nickel or nickel containing material to connect to the terminal of the cells because this is susceptible to spot welding.
A nickel or nickel containing metal strip is therefore employed to establish the connectivity between the copper conductor and the positive terminal of the cell. It is however then necessary to join the nickel or nickel containing metal strip to the copper in an effective manner that imparts low electrical resistance to the join. Ultrasonic welding has been found particularly useful in making such a join.
Ultrasonic welding of other materials is well known. In the preferred embodiment of this invention a nickel or nickel containing metal element is placed on the copper element between the anvil and the sonitrode of the ultrasonic welding system. The sonitrode is then forced downwards onto the area where the join is to be effected to subject a pneumatic squeeze to the two metals. The ultrasonic radiation is then applied and the optimum frequency that should be applied and the power duration depends upon the thickness of the copper element and the nature and thickness of the nickel or nickel containing metal element. Typically in the preferred embodiment of the invention where the ultrasonic welding is used to produce connectors for multi-cell battery systems where the copper sheet may be up to 1 millimeter thick and the nickel or nickel containing metal strip may also be up to 1 millimeter thick an effective weld can be produced in about one quarter of a second.
In a particular embodiment the present invention provides a connector plate for use in a battery module comprising a copper plate provided with a series of holes positioned to correspond to the upper terminals of the cells within the battery module provided with a nickel or nickel containing metal connector strip bridging the holes, said strip being weldable to the upper terminals of the cells to establish electrical contact with the cell wherein the copper plate and the nickel or nickel containing metal strip are joined by ultrasonic welding. In a preferred embodiment which is particularly useful when the connector plate is to be used in high power systems the nickel or nickel containing metal strip does not totally cover the holes in the copper plate to provide ventilation channels which can allow the flow of a cooling fluid through a battery module.
The battery systems which employ connector plates according to the present invention can have varying power outputs .If the battery systems are used to drive vehicles different power outputs are required to drive light vehicles such as golf carts, milk floats and light automobiles than are required to drive heavy automobiles and heavy goods vehicles. Furthermore, different power outputs may be required if the battery system is to be used as a power supply component in a hybrid vehicle in which the battery system can be charged when the vehicle is operating under another power source than if the battery system is to be the sole source of power. In addition the need for ventilation can depend upon the power output required; low power full electric vehicles such as golf carts, milk floats and light vehicles may not require ventilation. Higher power hybrid vehicles or plug in hybrid vehicles where cooling (ventilation) holes and fluid flow are important.
The power requirements are given what are known as "C" ratings. If the battery has a capacity of 40 KWh and it is powering a motor capable of 40 KW the application rating for power draw is 1C. If it were an 80 KWh battery for the same application the power draw would be C/2. If a 20 KWh battery was powering a motor capable of 40 KW the application rating would be 2C. Typically high power electric vehicles such as hybrid vehicles (HEV) have a rating of about 3OC. Plug in hybrid vehicles (PHEV) have a rating of from 5C to 10C whereas electric vehicles (EV) typically have a rating from 1C to 5C more typically from 1C to 2C.
In addition different system lifetimes between system recharges may be required according to the nature of the vehicle. Use of the connector plates of this invention enables the weight of the battery systems to be selected to minimise the impact on vehicle speed and any increase the fuel consumption when the battery system is used in a hybrid vehicle. A battery system employing the present invention has the benefit of flexibility concerning the number, capacity and size of cells that can be employed in a module and the number of modules that can be employed.
Traditional battery systems for powering of vehicles are bulky and require the provision of a special locator within the vehicle. The modular system enabled by the present invention has the added benefit that modules or batches of modules may be located at different positions within the vehicle and they may be connected by wiring to secure the
desired output of the entire battery system. In this way space can be saved within the vehicle structure. For example modules or batches of modules may be mounted on various structural components of the vehicle such as frame rails and pillars, around a drive shaft and other similar positions. In a preferred embodiment the battery system is provided in a box preferably of glass fibre reinforced plastic to provide the necessary strength and insulation and can withstand the temperatures which may be generated by the operation of the battery system which can reach 160cC.
Accordingly the present invention provides ultrasonic welding as an effective method of joining copper and nickel containing metals without having to create a heat based fusion weld. Ultrasonic welding creates an alloyed mix of the two materials where the weld is made. An added benefit of the present invention is that no third party binding medium such as solder is needed to effect the joint and the ultrasonic method of creating this junction provides a join of low resistance and high quality.
Whilst the invention has particular applicability to providing connector plates for battery powered vehicles and has been described in relation to its use in battery powered vehicles it can be used in other environments where battery power is used. Examples of other environments where the invention may be used include stationary and stand by power, industrial battery applications, aviation batteries, batteries for space and exploration, submarine and ship borne battery systems, telecommunication and portable power applications.
The present invention is illustrated by reference to the accompanying drawings in which
Figure 1 shows a copper connector plate overlaid with strips of nickel alloy ready for ultrasonic welding.
Figure 2 shows an ultrasonic weld being performed on the plate shown in Figure 1 at one of the locations where a weld is required.
Figure 3 shows the copper connector plate shown in Figure 1 with the nickel alloy strips welded to the plate in several positions.
Figure 1 shows a copper plate (1) provided with holes (2) overlaid with strips of nickel (3) and placed below the anvil (4) of an ultrasonic welding machine. The sonitrode (5) of the ultrasonic welding machine is positioned to deliver the ultrasound radiation to the location (6) where the weld is to be performed.
Figure 2 shows 4 locations (7) where welds have been performed and a weld being performed at location (6).
Figure 3 shows the final welded connector plate with the nickel strips (3) welded to the copper connector plate a locations (4) between the holes provided in the plate to correspond to the position of the terminals of the cells within a battery module.
Claims
1. The use of ultrasonic welding to join copper to a nickel or nickel containing metal.
2. A copper element joined to a nickel or nickel containing metal element by ultrasonic welding.
3. The use or an element according to Claim 1 or Claim 2 in which the copper is an electrical connector plate.
4. The use or an element according to Claim 3 in which a nickel or nickel containing metal is a strip welded to the copper plate to provide means to establish the connectivity between the copper element and the power source.
5. The use or an element according to Claim 4 in which the connection to the power source is the positive and/or negative terminal of a battery cell.
6. The use or an element according to any of the preceding claims wherein the copper element is up to 1 millimeter thick and the nickel or nickel containing metal strip is up to 1 millimeter thick.
7. A connector plate for use in a battery module comprising a copper plate provided with a series of holes positioned to correspond to the positive and/or negative terminals of the cells within the battery module provided with one or more a nickel or nickel containing metal connector strip or strips bridging the holes, said strip being weldable to the terminals of the cells to establish electrical contact with the cell and being joined to the copper plate by ultrasonic welding.
8. A connector plate according to Claim 7 in which the nickel or nickel containing connector strip or strips do not totally cover the holes and are dimensioned to provide a gap between the edge of the strip and the circumference of the hole. A connector plate according to Claim 7 or Claim 8 in which no third party binding medium is used to effect the joint between the copper and the nickel or nickel containing metal.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0806087.3 | 2008-04-03 | ||
GB0806087.3A GB2458942B (en) | 2008-04-03 | 2008-04-03 | Improvements in or relating to battery modules |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2009121614A1 true WO2009121614A1 (en) | 2009-10-08 |
Family
ID=39433082
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2009/002457 WO2009121614A1 (en) | 2008-04-03 | 2009-04-03 | Improvements in or relating to joining copper and nickel containing metals |
Country Status (2)
Country | Link |
---|---|
GB (1) | GB2458942B (en) |
WO (1) | WO2009121614A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2013018003A (en) * | 2011-07-07 | 2013-01-31 | Hitachi Ltd | Metal-bonded structure and method for manufacturing the same |
CN108878757A (en) * | 2018-07-27 | 2018-11-23 | 上海精虹新能源科技有限公司 | Cupro-nickel composite joint piece |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
NL2028136B1 (en) | 2021-05-04 | 2022-11-10 | Leydenjar Tech B V | Method for joining an electrode tab to a current collector using ultrasonic welding, an electrode assembly for a battery, and use of the assembly |
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GB866673A (en) * | 1956-09-05 | 1961-04-26 | James Byron Jones | Method and apparatus employing vibratory energy for bonding metals |
US20030111512A1 (en) * | 2001-12-18 | 2003-06-19 | Ntk Powerdex, Inc. | Method of connecting electric leads to battery tabs |
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US20080063932A1 (en) * | 2006-09-07 | 2008-03-13 | Hitachi Vehicle Energy, Ltd. | Assembled battery |
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EP0428908A1 (en) * | 1989-10-30 | 1991-05-29 | Mitsubishi Jukogyo Kabushiki Kaisha | Heat transfer pipe and method of making the same |
JP2002011582A (en) * | 2000-06-30 | 2002-01-15 | Sony Corp | Device of ultrasonic joining for metal and method of ultrasonic joining for metal |
AU2003299987A1 (en) * | 2003-01-03 | 2004-08-10 | Nanopierce Technologies, Inc. | Ultrasonic bonding of electrical devices |
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2008
- 2008-04-03 GB GB0806087.3A patent/GB2458942B/en not_active Expired - Fee Related
-
2009
- 2009-04-03 WO PCT/EP2009/002457 patent/WO2009121614A1/en active Application Filing
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
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GB866673A (en) * | 1956-09-05 | 1961-04-26 | James Byron Jones | Method and apparatus employing vibratory energy for bonding metals |
US20030111512A1 (en) * | 2001-12-18 | 2003-06-19 | Ntk Powerdex, Inc. | Method of connecting electric leads to battery tabs |
WO2006124663A2 (en) * | 2005-05-12 | 2006-11-23 | Tesla Motors, Inc. | Method and apparatus for mounting, cooling, connecting and protecting batteries |
US20080063932A1 (en) * | 2006-09-07 | 2008-03-13 | Hitachi Vehicle Energy, Ltd. | Assembled battery |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2013018003A (en) * | 2011-07-07 | 2013-01-31 | Hitachi Ltd | Metal-bonded structure and method for manufacturing the same |
CN108878757A (en) * | 2018-07-27 | 2018-11-23 | 上海精虹新能源科技有限公司 | Cupro-nickel composite joint piece |
Also Published As
Publication number | Publication date |
---|---|
GB2458942A (en) | 2009-10-07 |
GB0806087D0 (en) | 2008-05-14 |
GB2458942B (en) | 2013-04-03 |
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