High-Voltage Battery Cell Module Frame for Tolerance-Safe Connections
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Solution Overview
Problem
Existing high-voltage battery cell modules face challenges in efficiently linking cells for current, voltage, and temperature measurement while minimizing manufacturing costs and avoiding short circuits.
Innovation Solution
A cell module design featuring a flexible cell frame with injection-molded pre-embossed connector seats and double-stamped rosette connectors, allowing for manufacturing tolerance compensation and secure interconnection without additional insulation, using fusible pins for assembly and enabling cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cell connectors and mounting methods are used, then manufacturing precision is compromised due to tolerances, but adding compensation mechanisms increases device complexity
Solution Approach 1:
The connector employs a movable contact element that can shift position along the connector body to compensate for manufacturing tolerances. This dynamic adjustment mechanism allows the connector to adapt to position variations without requiring complex pre-positioning systems, thereby maintaining manufacturing precision while avoiding excessive device complexity
Solution Approach 2:
The connector design allows for parameter changes in the position of the contact element relative to the connector body. By enabling the contact element to move along the connector, the system can adjust its electrical and mechanical parameters to compensate for manufacturing tolerances, achieving precise connection without complex structural modifications
2Reliability
If additional insulation measures are added to prevent short circuits, then reliability improves, but manufacturing cost and device complexity increase
Solution Approach 1:
The cell frame structure provides inherent insulation properties through its material composition and geometric design. The frame itself serves the dual function of mechanical support and electrical insulation, eliminating the need for additional insulation components. This self-service approach maintains reliability by preventing short circuits while avoiding increased device complexity
Solution Approach 2:
The cell frame is designed to perform multiple functions simultaneously: mechanical support, structural integrity, and electrical insulation. By making the frame universal in its functionality, the patent eliminates the need for separate insulation components, thereby maintaining short circuit prevention capability while reducing device complexity and manufacturing cost
3Measurement precision
If cells are linked rigidly for measurement, then measurement precision is maintained, but flexibility in assembly and tolerance compensation is reduced
Solution Approach 1:
The electrical connection system incorporates movable contact elements that can adjust their position dynamically during assembly. This dynamic capability allows the system to maintain precise electrical measurements while adapting to variations in cell positioning and manufacturing tolerances, thereby preserving both measurement precision and assembly flexibility
Solution Approach 2:
The connector design includes preliminary positioning features such as guide elements and tolerance-compensating geometries that are built into the structure before final assembly. These preliminary actions ensure that even with flexible assembly procedures, the final electrical connection achieves the required measurement precision
4Reliability
If complex assembly procedures are used to ensure secure connection, then reliability improves, but productivity decreases
Solution Approach 1:
The connector and cell frame incorporate preliminary positioning features and self-aligning geometries that automatically ensure correct alignment during assembly. This preliminary action eliminates the need for complex alignment procedures and multiple assembly steps, thereby maintaining connection security while significantly improving assembly speed and productivity
Solution Approach 2:
The connection system is designed to self-align and self-secure during assembly through its geometric features and material properties. The connector automatically positions itself correctly relative to the cell frame and secures the connection without requiring complex external fixtures or multi-step procedures, thus achieving reliable connections with simple, fast assembly processes
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 flexible and secure cell interconnection for measurement while reducing manufacturing costs and preventing short circuits, facilitating efficient production and assembly of high-voltage batteries.
Implementation Method 1
a heating device for heating the material application in order to melt the material application and secure the cell connector (15) in the cell connector seat (17)
Data Source
AI summary
A cell module for a high-voltage battery having round cells polarized on one side and a common cell frame with cell connectors. The cell frame connects the cell connectors in a predefined arrangement. The cell connectors are configured for a low-voltage contact of the round cells. Also described is a method for producing the module, a corresponding use of the module and a corresponding high-voltage battery.