Battery Cell Contact Element Layout for Stable Fuse Sections
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Solution Overview
Problem
Existing methods for arranging contact elements in battery stacks are costly and complex, with limitations in introducing securing sections with reduced cross sections, which affect mechanical stability and safety against overloads.
Innovation Solution
A method involving a contact element with a contact plate section, transition section, and positive pole section, where the securing opening is introduced after the element is arranged on the battery cell, allowing for smaller, more precise fuse sections and increased safety without compromising mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact element is manufactured completely before arrangement, then the mechanical stability is maintained, but the fuse section size is limited and safety against overloads is reduced
Solution Approach 1:
The contact element is divided into a first contact element (contact plate section) and a second contact element (positive pole section with fuse section), which are arranged separately and then connected. This segmentation allows the fuse section to be optimized for safety without compromising the mechanical stability of the contact plate section.
Solution Approach 2:
The contact plate section and positive pole section are prepared separately with their respective functions optimized in advance. The contact plate section is designed for mechanical stability, while the positive pole section incorporates the fuse section for safety. These pre-prepared sections are then assembled together.
2Reliability
If securing openings are introduced in the transition section, then the fuse section with reduced cross-section is created, but the mechanical stability of the contact element is impaired
Solution Approach 1:
By separating the contact element into two independent sections that are arranged after manufacturing, the need to introduce securing openings in the transition section is eliminated. Each section maintains its mechanical integrity while fulfilling its specific function.
Solution Approach 2:
Instead of creating the fuse section by removing material (introducing openings) from a complete contact element, the invention inverts the approach by assembling two separately manufactured sections, where the fuse section is inherently designed with the reduced cross-section without compromising the overall mechanical stability.
3Reliability
If the contact element is manufactured as a complete unit, then the manufacturing process is simple, but the fuse section cannot be optimized for smaller sizes
Solution Approach 1:
The contact element is segmented into two separately manufacturable sections, allowing the fuse section to be optimized with smaller dimensions and reduced cross-section for enhanced safety functionality, while the contact plate section maintains its structural requirements.
Solution Approach 2:
Different sections of the contact element are manufactured with different qualities and characteristics optimized for their specific functions. The contact plate section is optimized for mechanical stability and electrical conductivity, while the positive pole section with fuse section is optimized for safety with reduced cross-section.
4Reliability
If larger fuse sections are used to maintain mechanical stability, then the mechanical strength is sufficient, but the safety against overloads is reduced
Solution Approach 1:
The contact element is divided into separate sections, allowing the fuse section to be independently optimized with reduced cross-section for safety without requiring large dimensions for mechanical stability, as this function is fulfilled by the separate contact plate section.
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
This approach simplifies the arrangement of contact elements, enhances mechanical stability, and provides increased safety against overloads by allowing smaller, more effective fuse sections that can melt under high currents, reducing manufacturing costs and improving assembly efficiency.
Implementation Method 1
If the electrical load is too high, particularly if the current flowing is too high, the contact element will melt at this reduced cross-section, thereby interrupting the electrically conductive connection.
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
The invention relates to a method for arranging a contact element (1) on a battery cell (60) of a battery layer (50) of a battery stack (40) for a battery device of a vehicle. The invention also relates to a contact element (1) for a battery cell (60) of a battery layer (50) of a battery stack (40) for a battery device of a vehicle, comprising a contact plate section (10), a transition section (20) and a positive pole section (30), wherein the contact plate section (10) surrounds the transition section (20) and the transition section (20) surrounds the positive pole section (30), and wherein the contact plate section (10) and the positive pole section (30) are arranged at a distance to one another and in parallel or at least substantially in parallel. The invention further relates to a battery stack (40) having at least one battery layer (50) with at least one battery cell (60), wherein a contact element (1) is arranged on the battery cell (60).