Battery Cell Connector Recessed Bridge Design
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Solution Overview
Problem
The uneven thermal expansion between plastic battery housings and bronze alloy electrical contact elements in electric vehicles leads to mechanical stresses and unreliable connections between battery cells due to differential expansion and contraction during temperature changes.
Innovation Solution
A cell connector with electrically conductive contact elements featuring a recessed area between the connecting bridge and contact tabs, allowing for flexibility and reduced mechanical stress, and made from materials with high tensile strength and low thermal stress relaxation, enabling reliable electrical connections between round cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical contact elements are made from bronze alloy and connected in a rigid manner, then electrical conductivity is ensured, but mechanical stresses occur due to differential thermal expansion with plastic battery housing
Solution Approach 1:
The patent applies this principle by creating a recessed area in the electrical contact element between the connecting bridge and contact tabs. This recessed area acts as a flexible zone that can deform to accommodate differential thermal expansion between the bronze alloy contact elements and plastic battery housing, thereby reducing mechanical stresses on the weld connection while maintaining electrical conductivity.
2Ease of manufacture
If the battery housing is made from plastic, then manufacturing ease and cost are improved, but thermal expansion differences cause mechanical stresses on electrical contact elements
Solution Approach 1:
The recessed area in the electrical contact element provides flexibility to absorb thermal expansion differences between the plastic housing and bronze contact elements, reducing mechanical stresses while allowing the use of lightweight plastic housing for easy manufacturing.
3Stability of the object's composition
If the electrical contact elements are rigid, then structural stability is maintained, but they cannot compensate for thermal expansion during temperature changes
Solution Approach 1:
The recessed area introduces a controlled flexible zone within the otherwise rigid electrical contact element. This allows the contact element to maintain overall structural stability while the recessed area provides localized flexibility to compensate for thermal expansion and contraction during temperature changes.
Solution Approach 2:
The patent applies local quality by creating a recessed area with different mechanical properties (higher flexibility) at a specific location between the connecting bridge and contact tabs, while the rest of the electrical contact element maintains its rigid, stable structure. This localized modification allows thermal expansion compensation without compromising overall structural integrity.
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 and flexible electrical connection that compensates for thermal expansion, reducing mechanical stress and ensuring a stable contact between battery cells, enhancing the performance and capacity of electric vehicle batteries.
Implementation Method 1
Since plastic has a much higher coefficient of thermal expansion than the bronze alloy of the electrical contact elements, the electrical contact elements expand or contract unevenly when exposed to heat during electrical loading of the battery cells or when the battery cools down.
Implementation Method 2
in an area between the electrically conductive connecting bridge and at least one contact tab adjacent to the electrically conductive connecting bridge material of the electrical contact element is recessed
Data Source
AI summary
A cell connector for connecting round cells of a battery includes a plurality of electrical contact elements that are each configured to electrically connect a first round cell to a second round cell. The each electrical contact element includes a contact base. The electrical contact elements can each be connected via the contact base to a positive terminal of the first round cell in a material-bonded manner. The electrical contact elements each includes a plurality of contact tabs, with which the electrical contact elements can each be contacted to a negative terminal of the second round cell. An electrical contact element is respectively connected via an electrically conductive connecting bridge to a further electrical contact element. In an area between the electrically conductive connecting bridge and at least one contact tab adjacent to the electrically conductive connecting bridge material of the electrical contact element is recessed.