Battery Cell Contacting Assembly With Integrated Sensor Mounting
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Solution Overview
Problem
Existing cell contacting systems for electrical battery modules lack efficient and cost-effective solutions for monitoring parameters like operating voltage and temperature, often requiring complex printed circuit boards and ribbon cables for sensor connections.
Innovation Solution
A cell contacting system with a carrier structure, cell contacting elements, power connections, and a measuring arrangement that includes sensor elements fastened to retaining elements on the cell contacting elements via welded or bonded connections, using standard electrical cables for connectivity, allowing for monitoring of battery module parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex printed circuit boards and ribbon cables are used for sensor connections, then measurement precision and reliability are improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The sensor element is integrated directly onto the cell contacting element, merging the monitoring function with the existing structural component. This eliminates the need for separate printed circuit boards and ribbon cables, reducing device complexity while maintaining measurement capability through direct electrical connection via the sensor line
Solution Approach 2:
The cell contacting element serves dual purposes: it provides mechanical/electrical connection for battery cells and simultaneously supports the sensor element for parameter monitoring. This multi-functionality reduces the need for additional dedicated monitoring components, simplifying the overall system structure
2Measurement precision
If complex printed circuit boards and ribbon cables are used for sensor connections, then measurement precision and reliability are improved, but manufacturing costs increase
Solution Approach 1:
By integrating the sensor element directly onto the cell contacting element, the patent eliminates the need for separate printed circuit boards and ribbon cable assemblies. This reduction in component count directly lowers manufacturing costs while maintaining the ability to measure parameters accurately through the sensor line connection
Solution Approach 2:
The patent extracts the sensor element from the complex PCB/ribbon cable assembly and places it directly on the cell contacting element. This extraction simplifies the manufacturing process by eliminating costly intermediate connection layers while preserving the essential measurement function
3Reliability
If sensor elements are connected via sensor lines to connection contacts, then measurement reliability is improved, but device complexity increases
Solution Approach 1:
The sensor element is pre-positioned and fastened directly onto the cell contacting element during assembly, establishing a reliable electrical connection through the sensor line before final system integration. This preliminary positioning ensures proper alignment and connection reliability while minimizing the complexity of subsequent assembly steps
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 solution simplifies the manufacturing process and reduces costs by enabling effective monitoring of battery module parameters through straightforward electrical and thermal connections, improving the monitoring of battery module functionality and performance.
Implementation Method 1
The sensor element is fastened on the at least one of the cell contacting elements by a retaining element formed on the at least one of the cell contacting elements
Implementation Method 2
fastened on the at least one of the cell contacting elements by a retaining element formed on the at least one of the cell contacting elements
Data Source
AI summary
A cell contacting system for an electrical battery module includes a carrier structure, a plurality of cell contacting elements arranged on the carrier structure and electrically contacting a plurality of battery cells, a plurality of power connections electrically connected to the cell contacting elements, and a measuring arrangement measuring a parameter of the electrical battery module. The measuring arrangement has a sensor element connected to a connection contact of the cell connecting system via a sensor line. A monitoring device is connectable to the measuring arrangement via the connection contact in order to monitor the parameter. The sensor element is connected to at least one of the cell contacting elements and measures the parameter. The sensor element is fastened on the at least one of the cell contacting elements by a retaining element formed on the at least one of the cell contacting elements.