Battery Cell Connector Clip Design for Tolerance Compensation
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Solution Overview
Problem
Existing battery systems face challenges in maintaining reliable and efficient electrical connections between cell terminals, particularly in high-voltage applications, due to manufacturing tolerances and operational movements, which can lead to increased forces and torques, requiring complex connectors and assembly processes.
Innovation Solution
A simple, detachable cell connector design utilizing a clip element with spring force for automatic and permanent contact-making, which can be made from steel or other materials, allowing for electrical conductivity or insulation, and featuring asymmetrical or symmetrical engagement sections for secure connections, potentially with a busbar for improved electrical resistance, and a securing element for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex cell connectors with plastic deformability and compensation elements are used to ensure reliable electrical connection and compensate for manufacturing tolerances and operational movements, then connection reliability is improved, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent extracts and eliminates the complex plastic deformability mechanisms and separate compensation elements from the cell connector design. By using a rigid connector body with precisely positioned engagement sections that directly engage with receiving sections on cell terminals, the invention removes unnecessary components while maintaining reliable electrical connection and tolerance compensation through the engagement geometry itself.
Solution Approach 2:
The connector is segmented into distinct engagement sections, each designed to engage with corresponding receiving sections on cell terminals. This segmentation allows each engagement section to be optimized for its specific function while maintaining overall simplicity, eliminating the need for complex unified structures with integrated plastic deformability.
2Reliability
If complex cell connectors with multiple components are used to ensure reliable connection, then connection reliability is improved, but the number of components increases and assembly becomes more difficult
Solution Approach 1:
The patent merges multiple functions into a single rigid connector body: electrical conduction, mechanical engagement, and tolerance compensation are all achieved through the integrated engagement sections and receiving sections geometry. This eliminates the need for separate plastic deformability mechanisms and compensation elements, reducing component count and simplifying assembly to a single engagement action.
3Reliability
If cell connectors with plastic deformability and compensation elements are used to compensate for manufacturing tolerances and operational movements, then connection reliability is improved, but forces and torques transmitted to cell terminals increase
Solution Approach 1:
The engagement sections and receiving sections are designed with predetermined geometric relationships that accommodate manufacturing tolerances and operational movements before excessive forces develop. The rigid connector with precisely positioned engagement sections absorbs tolerance variations through its geometry rather than transmitting destabilizing forces to the cell terminals.
4Ease of operation
If detachable cell connectors are used to allow easy disassembly and reusability, then ease of operation is improved, but connection reliability may be compromised
Solution Approach 1:
The patent employs a dynamic engagement system where rigid engagement sections can be inserted into and removed from corresponding receiving sections. This dynamic design allows for easy disassembly and reusability while maintaining reliable electrical connection during operation, as the rigid geometry ensures consistent electrical contact when engaged.
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
The solution provides a reliable, efficient, and easy-to-assemble connection that maintains electrical contact over the life of the battery, reduces component count, and simplifies manufacturing and fitting, while allowing for easy disassembly and reusability, thereby enhancing the functionality and reliability of battery systems.
Implementation Method 1
A simple, detachable cell connector design utilizing a clip element with spring force for automatic and permanent contact-making
Data Source
AI summary
A cell connector for an electrical or mechanical connection of cell terminals of battery cells is described. The cell connector is characterized by a clip element for fastening the cell connector to the cell terminals comprising a back section, a first limb section which is formed at a first end of the back section, having a first engagement section, and a second limb section, which is formed at a second end of the back section and is formed so as to be spaced apart from and opposite the first limb section, having a second engagement section, wherein the clip element is designed in such a way that it can at least partially surround the cell terminals.