Battery Arrangement With Insulating Connecting Element

Solution Overview

Problem

Existing battery arrangements for motor vehicles face challenges in establishing reliable and efficient electrical connections between flexible battery cells, often requiring complex soldering processes, which increase technical expenditure and reduce mechanical stability.

Innovation Solution

A battery arrangement featuring electrically insulating connecting elements with openings that securely route and clamp connection lugs using conductive contact elements, eliminating the need for soldering and allowing for reliable electrical connections with reduced technical effort, while also incorporating metallic cooling plates for thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If contact lugs are connected by soldering or mechanical means to form reliable electrical connections, then electrical reliability is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnection process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connecting element integrates both mechanical connection and electrical connection functions into a single component. The connecting element mechanically stabilizes the battery cell on the frame element while simultaneously providing electrical contact through its conductive portions, eliminating the need for separate soldering or mechanical connection steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connecting element serves multiple functions: it acts as a mechanical stabilizer for the battery cell, provides electrical contact through conductive portions, and serves as a structural connector between frame elements. This multi-functionality reduces overall system complexity while maintaining reliable electrical connections.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If contact lugs are connected by soldering or mechanical means to form reliable electrical connections, then electrical reliability is improved, but manufacturing cost increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The connecting element integrates both mechanical connection and electrical connection functions into a single component. The connecting element mechanically stabilizes the battery cell on the frame element while simultaneously providing electrical contact through its conductive portions, eliminating the need for separate soldering or mechanical connection steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connecting element appears to be a simple, easily manufacturable component that can be produced at low cost. By using a straightforward design with conductive portions that can be easily fabricated, the solution reduces manufacturing complexity and cost while maintaining reliable electrical connections.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If battery cells are arranged on frame elements with connecting elements, then mechanical stability is improved, but electrical connection complexity increases

Engineering Contradiction:

Improvemechanical stabilityVSAvoidelectrical connection complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The connecting element integrates both mechanical connection and electrical connection functions into a single component. The connecting element mechanically stabilizes the battery cell on the frame element while simultaneously providing electrical contact through its conductive portions, eliminating the need for separate soldering or mechanical connection steps.

Inventive Principle:

Principle #5Merging (Combining)

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 enables a mechanically stable and cost-effective battery arrangement with increased integration density, reliable electrical connections, and effective heat dissipation, preventing overheating and simplifying the connection process.

Implementation Method 1

The contact lugs can be clamped to the connecting element with a low level of technical expenditure by the conductive contact element... a reliable electrical connection between the connection lugs can be realized

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 2

A metallic cooling plate may be arranged between the battery cells to achieve cooling and to prevent overheating of the battery arrangement

Methodology Applied

Scientific EffectThermal Conduction: Conduction (thermal)

Data Source

PatentUS10573937B2Battery arrangement

Publication Date: 2020.02.25 DR ING H C F PORSCHE AG

AI summary

A battery arrangement (10) for a motor vehicle has a plurality of battery cells (12) for storing electrical energy. Each battery cell (12) has two flexible connection lugs (18) to make electrical contact with the battery cells (12). The battery cells (12) are arranged on surfaces of rigid plate-like frame elements (14). At least one connecting element (20) is arranged on one side of the frame elements (14) and is connected to the frame elements (14). The connecting element (20) is of electrically insulating design and has openings (24) through which the connection lugs (18) are routed. An electrically conductive contact element (28, 30; 42, 44) is secured to the connecting element (20) and electrically contacts the connection lugs (18).