Bimetallic Connector for Battery PCB Electrical Contact
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Solution Overview
Problem
Existing methods for electrically contacting a printed circuit board to a battery cell composite system are complex and expensive, particularly due to the need to connect different materials like copper and aluminum, which complicates the manufacturing process.
Innovation Solution
A mechanism using a bimetallic element, composed of two different materials such as copper and aluminum, fastened to the printed circuit board, which simplifies the electrical contact by eliminating the need for wire strands and providing a robust connection through a screw-based fastening system with a high-strength thread coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire strands and solder connections are used to electrically contact the printed circuit board to the battery cell composite system, then electrical contact can be established, but the manufacturing process becomes complex and expensive
Solution Approach 1:
The patent merges the electrical contact function and mechanical fastening function into a single integrated cell connector. The cell connector includes a connecting element for electrical contact and an integrated fastening element, eliminating the need for separate wire strands and solder connections. This integration simplifies the manufacturing process while maintaining reliable electrical contact between the printed circuit board and battery cell composite system.
Solution Approach 2:
The patent employs a bimetallic element comprising copper and aluminum layers. The copper layer provides excellent electrical conductivity for reliable electrical contact, while the aluminum layer offers lightweight properties and corrosion resistance. This composite material structure resolves the contradiction by enabling reliable electrical contact through the copper layer while simplifying manufacturing through the aluminum layer's ease of processing.
2Adaptability or versatility
If different materials like copper and aluminum are connected to establish electrical contact, then electrical contact between battery cell composite system and printed circuit board is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The bimetallic element integrates copper and aluminum in a single component structure. The copper layer ensures excellent electrical conductivity for adapting to different electrical requirements, while the aluminum layer provides ease of manufacturing through its lightweight and corrosion-resistant properties. This composite structure resolves the contradiction by combining material compatibility for electrical contact with manufacturing ease in a single integrated element.
Solution Approach 2:
The bimetallic element acts as an intermediary between the aluminum cell connector and the copper printed circuit board. It provides a transition layer that ensures good electrical contact between the two different materials while simplifying the manufacturing process by eliminating the need for complex joining processes between dissimilar metals.
3Reliability
If friction welding is used to contact wire strands to the cell connector, then electrical contact is established, but an additional passivating step is required to isolate humidity
Solution Approach 1:
The patent merges the electrical contact function and mechanical fastening function into a single integrated cell connector assembly. The connecting element provides electrical contact while the integrated fastening element provides mechanical securing, eliminating the need for separate friction welding and passivating steps. This integration reduces the number of process steps while maintaining contact stability.
Solution Approach 2:
The bimetallic element's copper-aluminum structure provides inherent corrosion resistance that reduces the need for additional passivating steps. The aluminum layer naturally forms a protective oxide layer that isolates humidity, while the copper layer ensures electrical conductivity. This material combination maintains electrical contact stability while simplifying the manufacturing process.
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 bimetallic element enables reliable and robust electrical contact between the battery cell composite system and the printed circuit board, reducing manufacturing complexity and preventing material corrosion, while allowing for automated and secure fastening.
Implementation Method 1
a bimetallic element which is fastened to the printed circuit board, at least one cell connector for connecting the battery cell composite system to the printed circuit board, wherein the cell connector contacts the at least one bimetallic element with a connecting element
Data Source
AI summary
A mechanism for electrically contacting a printed circuit board to a battery cell composite system comprises a printed circuit board, at least one bimetallic element which is fastened to the printed circuit board, at least one cell connector for connecting the battery cell composite system to the printed circuit board, wherein the cell connector contacts the at least one bimetallic element with a connecting element, and a fastening element for fastening the connecting element to the at least one bimetallic element.