Cell Contacting Unit Assembly With Adhesive-Sealed Busbar Access
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Solution Overview
Problem
The assembly of battery systems is burdensome due to the need for multiple individual components and complex connections, which can lead to increased production steps, potential errors, and space constraints in mobile applications.
Innovation Solution
A battery system comprising a battery pack with a cell contacting unit (CCU) featuring an electrically isolating carrier with busbars and measuring means, where the busbars and measuring means are mounted on one side and access openings on the opposite side allow for easy connection and adhesive closure, optionally including a plug for battery management module connection and a corrugated shape for degassing channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual components and complex connections are used for battery assembly, then electrical connectivity and protection functions are achieved, but assembly complexity and production burden increase
Solution Approach 1:
The patent combines multiple individual components (carrier, busbars, measuring means, touch protection elements) into a single integrated cell contacting unit. This merging reduces the number of separate assembly steps while maintaining all necessary electrical connectivity and protection functions, directly addressing the contradiction between reliability and assembly complexity.
Solution Approach 2:
The carrier structure serves multiple functions simultaneously: it provides mechanical support for busbars and measuring means, ensures touch protection through integrated coverings, and facilitates electrical connections. This multi-functionality eliminates the need for separate components for each function, reducing assembly burden while maintaining system reliability.
2Reliability
If multiple individual components are assembled through several steps, then complete battery system functionality is achieved, but production time and assembly burden increase
Solution Approach 1:
The cell contacting unit is pre-assembled with all electrical components (busbars, measuring means) and touch protection elements integrated before installation into the battery system. This preliminary action reduces production time by eliminating multiple separate assembly steps during final system assembly, while ensuring complete functionality is maintained.
3Ease of manufacture
If access openings are provided in the carrier for busbar connection, then electrical connection access is enabled, but touch protection is compromised
Solution Approach 1:
The patent introduces an adhesive as an intermediary substance that closes the access openings after busbar connections are established. This adhesive mediator maintains the electrical connections while simultaneously restoring the touch protection function, resolving the contradiction between connection access and protection.
Data Source
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AI summary
The present disclosure refers to a battery system (100) and a method of assembling a battery system (100). The battery system comprises a battery pack (10) including a plurality of battery cells with electrode terminals; and a cell contacting unit, CCU, (12) disposed on the battery pack (10). The CCU (12) comprises an electrically isolating carrier (14) at least covering the terminals of the battery cells, a plurality of busbars (16) electrically connecting the terminals of the battery cells and measuring means for detecting at least one physical property of the battery cells. The busbars (16) and the measuring means are arranged on a first side of the carrier (14) facing the battery cells and the carrier (14) comprises a plurality of access openings (18) for providing access to the busbars (16) from a second side of the carrier (14) opposite to the first side. The access openings (18) of the carrier (14) are closed by an adhesive.