Cell Contacting Unit Assembly With Integrated Battery Degassing
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Solution Overview
Problem
Conventional battery systems face challenges in efficient assembly due to the burdensome process of individually mounting multiple components, which can lead to errors and increased production time, while also requiring additional space for degassing channels and battery management modules.
Innovation Solution
A battery system featuring a cell contacting unit (CCU) with an electrically isolating carrier, busbars, and sensors, where the busbars and sensors are preassembled on one side of the carrier, allowing access through openings that are sealed with adhesive, and a battery management module connected via a plug, facilitating streamlined assembly and integrated degassing channels within the carrier's corrugated design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple components are individually mounted on the battery pack, then the battery system can be assembled with separate components, but the assembly process becomes burdensome and error-prone
Solution Approach 1:
The patent combines multiple separate components (cell contacting unit, battery management module, degassing channels) into a single integrated carrier structure. This merging reduces the number of individual mounting steps and components while maintaining all necessary functions, directly addressing the assembly burden described in the contradiction.
Solution Approach 2:
The carrier is designed as a multi-functional component that simultaneously serves as a mounting structure, electrical connection interface, sensor housing, and degassing channel. This universal design eliminates the need for separate components for each function, simplifying the overall assembly process while maintaining functional complexity.
2Ease of manufacture
If additional space is allocated for degassing channels and battery management modules, then these components can be properly installed, but the battery pack volume increases
Solution Approach 1:
The patent nests the battery management module and degassing channels within the carrier structure itself, rather than allocating separate external spaces for these components. The carrier acts as a container that houses multiple functions in a nested arrangement, reducing the overall battery pack volume while ensuring proper installation space for all components.
3Ease of manufacture
If access openings are provided in the carrier for busbar connection, then electrical connections can be made, but the carrier requires additional sealing with adhesive
Solution Approach 1:
The access openings are pre-formed in the carrier structure during carrier manufacturing, allowing busbar connections to be made from the opposite side without requiring additional opening or sealing steps. The adhesive sealing is applied as a preliminary protective measure rather than a post-connection requirement, streamlining the overall 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
This solution reduces assembly errors, simplifies the production process, and integrates degassing channels and battery management modules without additional components, enhancing the efficiency and compactness of the battery system.
Implementation Method 1
The access openings in the carrier are closed by an adhesive
Data Source
AI summary
A battery system includes: a battery pack including a plurality of battery cells having electrode terminals; and a cell contacting unit (CCU) on the battery pack. The CCU includes an electrically isolating carrier covering at least the terminals of the battery cells, a plurality of busbars electrically connecting the terminals of the battery cells, and sensors configured to detect a physical property of the battery cells. The busbars and the sensors are on a first side of the carrier facing the battery cells, and the carrier has a plurality of access openings for providing access to the busbars from a second side of the carrier opposite to the first side. The access openings in the carrier are closed by an adhesive