Battery Cell Contacting System Stiffness Reduction
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Solution Overview
Problem
The complexity and high costs associated with producing cell-contacting systems for vehicle battery modules, particularly due to the need for prefabricated connection elements with bent portions that reduce stiffness, lead to inefficient production processes.
Innovation Solution
A method involving electrically insulating support elements and a main body from which connection elements are produced, using cut-outs to reduce stiffness instead of bending, allowing for cost-effective and efficient production of connection elements that can be held in predetermined positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection elements are produced with bent portions to reduce stiffness, then the connection elements can accommodate thermal expansion and mechanical stresses, but the production process becomes more complex and costly
Solution Approach 1:
The connection element is segmented by introducing cut-outs that divide the main body into multiple sections. This segmentation reduces the stiffness of the connection element while maintaining its structural integrity, allowing it to accommodate thermal expansion and mechanical stresses without requiring complex bending processes
Solution Approach 2:
Instead of reducing stiffness by bending the connection element (adding complexity), the invention inverts the approach by using cut-outs to remove material strategically. This simplifies the production process while achieving the same stiffness reduction effect, eliminating the need for multi-stage punching and bending operations
2Ease of manufacture
If connection elements are prefabricated with bent portions, then they can be pre-assembled in the holding device, but the production time and material usage increase
Solution Approach 1:
The holding device is prepared in advance with positioning elements that guide the connection elements into their final positions. The cut-outs are designed to engage with corresponding features in the holding device, enabling rapid assembly without requiring complex pre-bending or multi-stage fabrication processes
Solution Approach 2:
The invention changes the geometric parameters of the connection element by introducing cut-outs with specific shapes and orientations. This modifies the stiffness and flexibility characteristics while maintaining compatibility with the holding device, allowing for faster production without sacrificing assembly ease
3Reliability
If multiple production stages including bending are used, then connection elements achieve proper flexibility, but material usage increases and costs rise
Solution Approach 1:
The connection element is segmented by introducing cut-outs that divide the main body into multiple sections. This segmentation reduces the stiffness of the connection element while maintaining its structural integrity, allowing it to accommodate thermal expansion and mechanical stresses without requiring complex bending processes
Solution Approach 2:
The invention uses a simple, cost-effective main body design that can be produced from standard materials without requiring expensive bending operations. The cut-outs are created through straightforward punching or cutting processes, reducing material waste and production costs while achieving the necessary flexibility
Data Source
AI summary
A method for producing a cell-contacting system for a battery module of a vehicle includes providing a plurality of connection elements for corresponding electrical connection of adjacent battery cells of the battery module, wherein the corresponding connection elements are produced such that they include a region having reduced stiffness; and providing a holding device for holding the connection elements, wherein the holding device is provided by electrically insulating support elements, initially at least one main body is provided and is connected to the support elements, and subsequently the connection elements are produced from the at least one main body.