Bi-metallic Cell Connector with Insulation Displacement Terminal
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Solution Overview
Problem
Existing cell connectors for battery systems have complex and large terminal elements, making it difficult to simplify the attachment of measuring lines, which increases costs, weight, and installation space, and requires soldering, screws, or stripping of insulation.
Innovation Solution
A cell connector with a first section made of aluminum or aluminum alloy and a second section made of copper, where the insulation displacement connector is permanently connected to the copper section, allowing for a small clamping connection and using LSA technology for quick and reliable electrical and mechanical contact without soldering or stripping, with options for connection methods like soldering, ultrasonic welding, pressing, or 'shooting'.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional terminal elements are used for connecting measuring lines, then reliable electrical connection is achieved, but device complexity and installation space increase
Solution Approach 1:
The patent combines the terminal element functions into an integrated structure where the insulation displacement connector and cell connector form a unified assembly. The terminal element is merged with the cell connector body, eliminating separate components and reducing overall device complexity while maintaining reliable electrical connection through the bonded aluminum-copper section construction.
Solution Approach 2:
The insulation displacement connector is nested within or integrated into the cell connector structure. The terminal element is positioned within the cell connector assembly, allowing compact arrangement and reducing installation space while ensuring proper electrical connection between measuring lines and battery cells.
2Ease of manufacture
If traditional clamping connections are used, then measuring lines can be attached, but cost and weight increase
Solution Approach 1:
The cell connector uses a composite construction with two different materials (aluminum and copper) bonded together. The aluminum section provides lightweight structural support while the copper section offers superior electrical conductivity for the terminal connection. This composite approach reduces overall weight compared to traditional solid copper connectors while maintaining ease of manufacture through standardized bonding processes.
3Productivity
If insulation displacement terminals are used, then quick connection is achieved, but permanent connection is required
Solution Approach 1:
The cell connector is segmented into two functional sections: an aluminum section for structural mounting to the battery cell and a copper section for electrical connection with the measuring line. This segmentation allows the insulation displacement terminal to be permanently connected to the copper section for quick assembly, while the entire cell connector can still be detached from the battery cell if needed, providing adaptability at different connection levels.
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 design reduces costs and weight, provides a better conductive connection, and allows for rapid, reliable, and cost-effective assembly of measuring lines, preventing corrosion by matching materials and ensuring a gas-tight connection.
Implementation Method 1
the first section and the second section being bonded to one another
Implementation Method 2
the cores of a measuring line can be pressed into the insulation displacement terminals using a special tool without having to strip the insulation from the measuring line beforehand. Due to sharp contacts in the metallic insulation displacement connector, the insulation of the wire is severed and a gas-tight connection is established.
Data Source
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AI summary
Cell connector (3) for a battery system (1) comprising several battery cells (2), wherein a terminal (6) of a battery cell (2) can be connected to a terminal (6) of an adjacent battery cell (2) by means of the cell connector (3), wherein an insulation displacement connector (7) is attached to the cell connector (3) for tapping the electrical voltage, wherein the cell connector (3) has a first section (3.1) made of a first material, and a second section (3.2) made of a second material different from the first material, wherein the first section (3.1) and the second section (3.2) are bonded together, wherein the insulation displacement connector (7) is electrically conductively connected to the second section (3.2) of the cell connector (3) and the insulation displacement connector (7) is permanently connected to the second section (3.2) of the cell connector (3).