Battery Covering Plate Holding Surfaces for Cell Connector Welding
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Solution Overview
Problem
Existing battery systems face issues with screw connections, which lead to increased resistance and temperature due to decreased loading force over time, and are cumbersome in mass production, especially when handling non-screwed cell connectors on a covering plate.
Innovation Solution
A battery system design featuring a covering plate with receiving regions having holding surfaces on both sides to securely hold cell connectors, allowing for easy placement and welding without additional positioning devices, and incorporating a voltage tapping unit with detachable measuring lines for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections are used to connect cell connectors to battery cells, then electrical connection is established, but the loading force decreases over time leading to increased transfer resistance and temperature
Solution Approach 1:
The patent replaces the mechanical screw connection system with a welding process. Instead of using screws that rely on friction and clamping force, the cell connectors are directly welded to the battery cell terminals, creating a permanent metallurgical bond that maintains consistent electrical conductivity without degradation over time.
Solution Approach 2:
The patent incorporates receiving regions with holding surfaces into the covering plate structure before assembly. These holding surfaces are pre-formed to precisely position and support the cell connectors during the welding process, ensuring proper alignment and facilitating the welding operation without requiring additional positioning devices.
2Reliability
If screw connections are used, then electrical connection is achieved, but the exterior dimensions increase due to screw heads
Solution Approach 1:
The patent removes the screw heads from the connection system. By using welding instead of screw connections, the protruding screw heads are eliminated entirely, allowing the covering plate to provide a flush, compact surface that reduces the overall exterior dimensions of the battery system.
3Volume of moving object
If non-screwed cell connectors are used on a covering plate, then compact dimensions are achieved, but mass production becomes inefficient and process reliability decreases
Solution Approach 1:
The covering plate is pre-formed with integrated receiving regions that include holding surfaces and positioning features. This preliminary preparation of the covering plate structure enables efficient assembly during mass production, as the cell connectors can be directly positioned and welded without requiring additional positioning devices or complex handling procedures.
4Volume of moving object
If non-screwed cell connectors are used, then compact dimensions are achieved, but handling during production becomes difficult
Solution Approach 1:
The receiving regions in the covering plate are pre-formed with holding surfaces that provide precise positioning and support for the cell connectors. This preliminary structuring of the covering plate creates natural handling features that facilitate easy placement and manipulation of the cell connectors during the assembly process.
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 enables a simple, reliable, and compact battery system production with improved electrical connections and reduced risk of cell connector dislodgment, facilitating efficient assembly and maintaining connectivity without the need for screw heads, thus addressing the limitations of screw-based connections.
Implementation Method 1
connecting the cell connectors by, for example, a welded process, to the poles of the battery cells
Data Source
AI summary
A battery system and a method for producing a battery system. The battery system has a plurality of battery cells, a covering plate provided on and/or over the battery cells to cover the battery cells, and cell connectors configured to electrically connect battery cells. The cell connectors are arranged in receiving regions of the covering plate.