Battery Cell End-Face Bracket Assembly for Reliable Pack Connections
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Solution Overview
Problem
Existing battery cell connectors for high-voltage battery devices in electric vehicles are either too costly to manufacture or cumbersome to assemble, with existing solutions being complex and not suitable for all battery cell arrangements.
Innovation Solution
A battery cell assembly with U-shaped brackets that are fastened to the end faces of battery cells, allowing for a cost-effective and reliable electrical connection through a materially bonded connection, ensuring a stable and permanent contact with pre-tensioned arms to compensate for tolerances and prevent air gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug connections are used to connect cell connectors to cell connecting elements, then reliable and permanent electrical connection is achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The invention extracts and eliminates the plug connection component from the system. Instead of using a separate plug connector that mates with a socket, the cell connector itself is designed with integrated contact elements that directly engage with the cell connecting elements, removing the need for complex plug connection mechanisms while maintaining reliable electrical contact
Solution Approach 2:
The invention merges the cell connector body and the contact elements into a single integrated component. The cell connector is designed with contact elements that are directly formed as part of the connector structure, combining multiple functions (connection, contact, and electrical conduction) into one element, thereby reducing manufacturing complexity
2Adaptability or versatility
If rail connections with grooved battery cells are used, then battery cells can be connected, but the design is complicated and costly and only suitable for directly adjacent cells
Solution Approach 1:
The cell connector is designed as a universal connection element that can accommodate different battery cell types and arrangements. The contact elements are configured to engage with various cell connecting element geometries, and the connector body can adapt to different spacing configurations, making the same connector design suitable for both directly adjacent and non-adjacent cell arrangements
Solution Approach 2:
The invention transitions from a two-dimensional rail connection system (requiring grooves in the cell connection region) to a three-dimensional point-to-point connection system. The contact elements can extend in multiple directions and engage with cell connecting elements at various positions, allowing connection of cells that are not necessarily adjacent in the assembly
3Reliability
If complex cell connectors with plug connections are used, then reliable electrical connection is achieved, but manufacturing costs increase
Solution Approach 1:
The cell connector is designed as a simple, inexpensive component that can be manufactured using cost-effective processes. The contact elements are formed as integral parts of the connector body using simple forming or stamping operations, eliminating the need for expensive multi-component assemblies. The design accepts that the connector is a single-use component that remains attached to the cell assembly, optimizing for low manufacturing cost rather than reusability
Data Source
AI summary
A battery cell assembly includes a plurality of battery cells, wherein the battery cells each include at least one first cell connecting element and at least one second cell connecting element. The cell connecting elements of the battery cells are each disposed on the end face side of the battery cells. Battery cells disposed in pairs are disposed opposite to a respective cell connecting element. An electrically conductive bracket is fastened at least to the oppositely disposed cell connecting elements as a cell connector. The first bracket of a first battery cell of the battery cells disposed in pairs surrounds and makes electrically conductive contact with the second bracket of the opposite second battery cell of the battery cells disposed in pairs.