Cascading Cell Connectors for Battery Module Thermal Loads
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Solution Overview
Problem
Battery module connectors face challenges in accommodating thermal and mechanical loads while maintaining electrical conductivity, often requiring high-quality materials that are costly and complex to produce, especially when dealing with alternating loads and varying cell volumes.
Innovation Solution
A connector system utilizing a cascading arrangement of different cell connector types, where each type connects a progressively larger number of terminals, allowing for efficient current density reinforcement through multi-layer configurations and material savings, with compensating sections designed for thermal and mechanical flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-quality materials are used for cell connectors to ensure electrical conductivity and reliability, then the electrical performance and reliability are improved, but the material costs and production complexity increase
Solution Approach 1:
The cell connector is divided into multiple functional sections: rigid contact sections for electrical connection, flexible compensating sections for thermal/mechanical accommodation, and connection sections for joining. This segmentation allows each part to be optimized independently, using high-quality materials only where needed for electrical conductivity while reducing overall material complexity
Solution Approach 2:
Different sections of the cell connector have different material properties and structural characteristics. The contact sections use high-quality conductive materials for reliable electrical connection, while the compensating sections use more flexible, cost-effective materials that can accommodate thermal expansion and mechanical loads, achieving local optimization of material usage
2Reliability
If cell connectors are designed to accommodate thermal and mechanical loads with alternating loads, then the reliability under varying conditions is improved, but the structural complexity and material requirements increase
Solution Approach 1:
The cell connector incorporates flexible compensating sections that can dynamically adapt to thermal expansion and mechanical loads. These sections are designed with inherent flexibility to accommodate volume variations in individual cells under alternating loads, maintaining reliable electrical connection without requiring overly complex rigid structures
Solution Approach 2:
The cell connector features a nested structure where compensating sections are integrated within the overall connector geometry. The compensating sections are positioned within the structure to accommodate thermal and mechanical variations without adding external complexity, allowing the connector to handle alternating loads efficiently
3Ease of manufacture
If standardized cell connectors are used across different positions in the battery module, then the manufacturing ease and assembly simplicity are improved, but the ability to optimize for different current density requirements is reduced
Solution Approach 1:
The cell connector is designed as a universal component that can be used at different positions in the battery module while adapting to local requirements. The standardized connector type can function in various configurations and positions, providing both manufacturing simplicity and adaptability through its modular, multi-functional design
Solution Approach 2:
While maintaining a standardized connector design for ease of manufacture, the connector can be configured with different parameters such as the number and arrangement of contact sections, flexible sections, and connection points. This allows optimization for different current density requirements at various module positions without requiring entirely different connector types
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 achieves high reliability and reduced material complexity by enabling efficient current transmission and accommodating thermal loads, while minimizing material usage and production costs through standardized, stackable connectors with elastic compensating sections.
Implementation Method 1
each comprising a number m of contact sections 81, which are mutually connected by (m-1) compensating sections 82, in particular designed as elastic elements
Data Source
AI summary
A connector system for a battery module has a number of cell connectors of different successive cell connector types in order to form one or more electric contacts with one or more connections of one or more individual cells of the battery module, in particular for a power-transmitting tap in which each cell connector of a subsequent cell connector type is designed to electrically connect a larger number of connections of individual cells than the number of connections which can be connected by each cell connector of a preceding cell connector type. Each cell connector of a preceding cell connector type can be stacked and/or nested on a cell connector of a subsequent cell connector type in an assembly direction perpendicular to the main direction of extension.