Bimetallic Battery Cell Connector for Swelling-Stable Clamping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery cell connectors are prone to mechanical stress and instability due to swelling and mechanical loads, leading to potential breakage, and require complex holding devices for stability, which are error-prone and costly to manufacture.
Innovation Solution
A bimetallic terminal clamp with a receiving area made from high yield strength material for clamping and a connection area suited for material bonding with the battery cell terminal, using different metal materials for optimal spring properties and conductivity, and employing friction welding for a stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a material bond connection (welding) is used to connect battery cell connectors, then low contact resistance is achieved, but mechanical stability deteriorates under vibrations and sustained mechanical stress
Solution Approach 1:
The terminal clamp is constructed as a composite structure combining a first metal material (e.g., aluminum or aluminum alloy) for the clamping surface that contacts the flat part, and a second metal material (e.g., steel or steel alloy) for the connection area that attaches to the battery cell terminal. This composite construction allows the clamping surface to provide excellent spring properties and electrical contact while the connection area provides superior mechanical strength and welding properties, thereby resolving the contradiction between low contact resistance and mechanical stability.
2Reliability
If a holding device is added to reduce mechanical stress from swelling, then connection stability improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The terminal clamp incorporates a receiving area with specific local geometric features designed to accommodate dimensional changes of the flat part during swelling. The receiving area includes a bottom surface and side surfaces that form a cavity allowing the flat part to expand into it, thereby absorbing swelling stresses locally without requiring additional holding devices. This local quality adaptation resolves the contradiction by integrating swelling compensation directly into the clamp structure.
Solution Approach 2:
The terminal clamp is designed with elastic deformation capability in the receiving area, allowing it to dynamically adapt to dimensional changes of the flat part during thermal expansion and swelling. The clamp can elastically deform to accommodate these changes while maintaining clamping force, providing continuous stability without complex mechanical holding devices.
3Adaptability or versatility
If different metal materials are used for clamping and connection areas, then optimal spring properties and conductivity are achieved, but manufacturing complexity increases
Solution Approach 1:
The terminal clamp is segmented into distinct functional areas: a clamping surface area made of first metal material optimized for spring properties and electrical contact with the flat part, and a connection area made of second metal material optimized for welding to the battery cell terminal. This segmentation allows each area to be manufactured from the most suitable material for its specific function, resolving the contradiction between material property optimization and manufacturing complexity through targeted material selection.
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 provides a low-weight, low-resistance, and stable electrical connection with reduced manufacturing effort, enabling fully automated production and assembly, while withstanding mechanical stress and thermal expansion without compromising the electrical connection.
Implementation Method 1
A cell connector is usually a flat part, which is arranged between the terminals of the battery cells. The change in length of the flat part caused by the temperature change leads to a mechanical stress of the connection of the flat part with the battery terminal
Implementation Method 2
The holding force is exerted on the flat part in particular by a spring force
Implementation Method 3
employing friction welding for a stable connection
Data Source
AI summary
The present invention relates to a battery cell connector having at least two terminal clamps, each having a receiving area and a connection area, and at least one flat part, wherein the receiving area of at least one of the terminal clamps is arranged for clampingly receiving the flat part, and the connection area of at least one of the terminal clamps is arranged for connecting to a pole of a battery cell in a material bond.