Battery Cell Frame Receptacles With Spacer-Protected Fuse Contacts
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Solution Overview
Problem
Existing battery cell connection methods risk error propagation due to fuse bridging by battery cell windings during faults and require specific pole alignment for material connection, limiting reliability and safety.
Innovation Solution
Incorporating protective elements with spacers to spatially separate fuse connection points and using connecting conductors with spring tongues to ensure secure, pole-independent connections, along with locking hooks for independent contact spring positioning and centering projections for tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contact spring is used to connect battery cell end sections, then electrical connection between cells is achieved, but the fuse connection points may be bridged by protruding battery cell coils during faults, causing error propagation
Solution Approach 1:
A protective element is introduced as an intermediary component between the battery cell and the contact spring. This protective element includes a spacer that actively prevents the battery cell coil from reaching the fuse connection points, thereby eliminating the harmful bridging effect while maintaining electrical connectivity through the contact spring mechanism
Solution Approach 2:
The protective element with its spacer is positioned in advance to counteract the potential harmful action of the battery cell coil protruding toward the fuse connection points. By establishing this preliminary protective barrier, the system prevents fault propagation before it can occur during outgassing or other fault conditions
2Reliability
If material connection is made at the positive pole contact protruding opposite the end face, then electrical connection is achieved, but the battery cell may be damaged due to necessary energy input
Solution Approach 1:
The protective element serves as a mediator that enables electrical connection through the contact spring and connecting conductor while simultaneously protecting the battery cell from excessive energy input during the connection process. The spacer component specifically positions the connection point to allow controlled energy transfer without damaging the battery cell
Solution Approach 2:
The protective element provides localized protection at the critical connection area where energy input occurs. The spacer creates a specific geometric configuration that concentrates the connection energy away from the battery cell casing, allowing reliable electrical contact without local overheating or damage to the battery cell
3Reliability
If a protective element with spacer is added to separate fuse connection points, then fault propagation is prevented, but device complexity increases
Solution Approach 1:
The protective element combines multiple functions into a single integrated component: it provides mechanical support for the contact spring, creates the necessary spacer distance to prevent coil bridging, and offers protection during the connection process. This merging of functions reduces the need for separate protective components and simplifies the overall assembly process
Solution Approach 2:
The protective element is designed as a universal component that serves multiple purposes: structural support, electrical isolation, mechanical positioning of the contact spring, and protection during welding or connection operations. This multi-functionality reduces the total number of components needed in the battery cell connection system
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
Prevents error propagation by maintaining electrical isolation after fuse melting and allows reliable, efficient connections without damaging battery cells, while enabling parallel and series connections with enhanced safety and tolerance compensation.
Implementation Method 1
the contact spring is usually held under tension between the connection points so that the conductor sections adjacent to the connection points retract from each other toward the connection points after melting
Implementation Method 2
it is proposed that the connection point of the contact spring supported by the spacer be connected to a contact plate via a weld point
Data Source
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AI summary
A device is described comprising a frame (1) that has receptacles for the end faces of battery cells (2) aligned parallel with respect to their longitudinal axis. To ensure that fault propagation is reliably independent of the position of the electrical poles of the battery cells (2) and their electrical connection, it is proposed that each receptacle of a first group (3a) has a protective element (7) covering the end face of the received battery cell (2) opposite a contact spring (4), which on its side opposite the battery cell (2) includes a spacer (8) for spatially separating the two connection points (6a, 6b) of a fuse (5) formed by the contact spring (4).