Battery Connecting Element With Compacted Individual Wires

Solution Overview

Problem

Existing battery connection methods require additional components for tolerance compensation, increasing production complexity, weight, and electrical resistance due to multiple joints and rigid connections, which can lead to mechanical stress and reduced service life.

Innovation Solution

A connecting element comprising multiple individual wires compacted in regularly spaced connection areas, allowing direct contact with electrical poles and providing flexibility to compensate for tolerances without additional components, while maintaining low contact resistance through compacted areas with properties similar to solid busbars.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional compensating elements are introduced between battery cells and busbars, then tolerance compensation is improved, but device complexity and manufacturing effort increase

Engineering Contradiction:

Improvetolerance compensationVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The busbar is integrated directly with the battery cell connector, eliminating the need for separate compensating elements. The busbar itself is designed with flexibility to accommodate tolerances, merging the functions of electrical connection and tolerance compensation into a single component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar serves multiple functions simultaneously: it provides electrical connection, compensates for position tolerances, and absorbs mechanical stresses. This multi-functionality eliminates the need for additional dedicated compensating components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If additional compensating elements are introduced, then tolerance compensation is improved, but weight increases

Engineering Contradiction:

Improvetolerance compensationVSAvoidbattery weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The busbar is integrated directly with the battery cell connector, eliminating the need for separate compensating elements. The busbar itself is designed with flexibility to accommodate tolerances, merging the functions of electrical connection and tolerance compensation into a single component.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If additional compensating elements are introduced, then tolerance compensation is improved, but electrical resistance increases due to multiple joints

Engineering Contradiction:

Improvetolerance compensationVSAvoidelectrical resistance

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The busbar is integrated directly with the battery cell connector, eliminating the need for separate compensating elements. The busbar itself is designed with flexibility to accommodate tolerances, merging the functions of electrical connection and tolerance compensation into a single component.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If rigid busbars are used for battery cell connections, then electrical connection is improved, but mechanical stress on electrical poles increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidmechanical stress on electrical poles

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The busbar's physical parameters are changed to incorporate flexibility while maintaining electrical conductivity. The busbar is designed with controlled flexibility to absorb mechanical stresses from relative movements, preventing stress concentration on the electrical poles while ensuring reliable electrical connection.

Inventive Principle:

Principle #35Parameter changes

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 simplifies battery structure, reduces mechanical stress, and achieves low contact resistance with a flexible yet robust connection that compensates for tolerances in all directions, enhancing the battery's operational reliability and service life.

Implementation Method 1

The connecting element comprises a multiplicity of individual wires which are compacted in a respective connection area... providing flexibility to compensate for tolerances

Methodology Applied

Scientific EffectFlexibility: Elasticity

Implementation Method 2

maintaining low contact resistance through compacted areas with properties similar to solid busbars

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentEP2823523B1Battery having a connecting element comprising multiple individual wires

Publication Date: 2015.09.23 AUDI AG

Figure 1~2
Figure 3

AI summary

The invention relates to a battery (10), in particular for a vehicle, having at least two battery cells (12) and having at least one connecting element (16) that connects at least one electrical terminal (14) of a first battery cell (12) to an electrical terminal (14) of at least one further battery cell (12). The connecting element (16) comprises a plurality of individual wires (18) that are compacted in a respective connecting area (20). The connecting element (16) is in contact with the respective electrical terminal (14) of the battery cell (12) in the respective connecting area (20) of said connecting element. The invention further relates to a method for making such a battery (10).