Battery Cell Busbar Mounting for Multi-Direction Tolerance Compensation
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Solution Overview
Problem
Existing technologies fail to effectively compensate for tolerances and protect battery cells from mechanical loads in traction batteries, leading to potential damage and inefficiencies in electrical connections.
Innovation Solution
A connecting device with a busbar and fastening mechanism that allows for tolerance compensation in multiple spatial directions, including a rotatable and elongate design, and a housing that provides electrical insulation and protection against mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid connecting elements are used to electrically connect battery cells, then electrical connection is achieved, but tolerance compensation between cells is insufficient leading to assembly difficulties
Solution Approach 1:
The busbar's geometric parameters are changed to include an elongate hole instead of a standard circular hole, allowing positional adjustment. The connecting element's shape is modified to accommodate tolerance variations in the battery cell poles' positions while maintaining electrical conductivity
Solution Approach 2:
The connecting device incorporates rotational freedom at its ends, allowing it to adapt dynamically to positional variations of the battery cell poles. This dynamic adjustment capability enables the rigid busbar to compensate for assembly tolerances without sacrificing connection reliability
2Reliability
If battery cells are rigidly connected to each other, then electrical connection is established, but mechanical loads can damage the battery cells
Solution Approach 1:
The housing acts as an intermediary between the rigid busbar and the battery cells, absorbing mechanical loads and protecting the cells from damage. The housing provides a compliant interface that decouples the rigid electrical connection from the battery cell structures
Solution Approach 2:
The housing is designed to beforehand cushion and distribute mechanical loads before they can reach the battery cells. This protective structure prevents direct transmission of mechanical stresses to the vulnerable cell components
3Adaptability or versatility
If connecting devices are designed with tolerance compensation capabilities, then assembly flexibility is improved, but device complexity increases
Solution Approach 1:
The busbar serves multiple functions simultaneously: it provides electrical connection, enables tolerance compensation through its elongate hole geometry, and allows rotational adaptation. This multi-functionality reduces the need for additional separate components, thereby limiting complexity increase
4Reliability
If busbars are directly connected to battery cells without protection, then electrical connection is achieved, but the battery cells are exposed to mechanical damage
Solution Approach 1:
The housing serves as a protective intermediary between the busbar and the battery cells, shielding the cells from mechanical damage while allowing the busbar to maintain efficient electrical connection. This protective layer decouples the electrical function from mechanical vulnerability
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 effectively compensates for tolerances and protects battery cells from mechanical loads, ensuring stable electrical connections and reducing the risk of damage while maintaining electrical insulation.
Implementation Method 1
the connecting device is designed to compensate for tolerances between two battery cells of the traction battery in at least two spatial directions
Implementation Method 2
The connecting device furthermore comprises a housing, which completely encloses the busbar... the housing serves for protection against direct contact and is in particular designed to electrically insulate the busbar
Implementation Method 3
The connecting device furthermore comprises a fastening device, via which the connecting device can be fastened to a housing component or a structural component of the traction battery
Data Source
AI summary
A connecting device for battery cells of a traction battery compensates for tolerances between two battery cells in at least two spatial directions. The connecting device includes a bus bar, the first end of which is designed to be electrically connected to a first battery cell, and the second end of which is designed to be electrically connected to a second battery cell to electrically interconnect the two battery cells, and includes a fastening device via which the connecting device can be fastened in various relative positions to a housing component or a structural component of the traction battery for the purpose of tolerance compensation.