Cell Connector Snap Spring Thermal Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cell contact arrangements for high-voltage energy storage modules are costly and complex, lacking a flexible and modular structure for reliable electrical connections between electrochemical storage cells, particularly in high-voltage battery systems for vehicles.
Innovation Solution
A cell contact arrangement featuring a carrier plate with snap-action springs and locking lugs that securely fix cell connectors, allowing for flexible positioning and expansion during heating, and enabling easy assembly and connection of multiple terminals in series or parallel configurations using preassembled metal connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cell connectors are rigidly fixed in the carrier plate, then positioning precision is improved, but thermal expansion stress causes distortion and connection failure
Solution Approach 1:
The patent transforms the rigid fixed connection into a dynamic spring-loaded connection. The cell connector includes a spring element that maintains constant contact pressure with the connection terminals while accommodating thermal expansion. This dynamic mechanism allows the connector to adapt to dimensional changes during welding and operation, preventing distortion and maintaining reliable electrical connection.
Solution Approach 2:
The spring constant and pre-compression force of the spring element are carefully selected to balance positioning stability and thermal expansion accommodation. The elastic deformation parameter of the spring is optimized to absorb thermal stress while maintaining sufficient contact pressure for reliable electrical connection throughout the operating temperature range.
2Reliability
If complex fastening mechanisms are used to secure cell connectors, then connection reliability is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines the positioning, fastening, and electrical connection functions into a single integrated cell connector assembly. The spring element simultaneously provides mechanical retention and electrical contact, eliminating the need for separate fasteners and reducing assembly steps. This merging of functions achieves reliable connection while simplifying the overall structure and manufacturing process.
Solution Approach 2:
The spring-loaded design enables self-adjusting connection pressure and self-retention without additional fastening operations. The spring automatically compensates for dimensional variations and maintains optimal contact force, eliminating the need for complex adjustment mechanisms or multiple fastening steps during assembly.
3Adaptability or versatility
If multiple separate components are used for cell contact arrangement, then adaptability is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The cell connector is designed as a universal module that can accommodate different connection terminal configurations through the spring mechanism's inherent adaptability. The same basic connector design works for various terminal shapes and positions, eliminating the need for multiple specialized components and enabling rapid assembly across different battery pack designs.
Solution Approach 2:
The spring element is pre-loaded during manufacturing to provide immediate retention and electrical contact upon installation. This preliminary action ensures that the connector is securely positioned and electrically connected in a single assembly step, eliminating the need for subsequent adjustment or fastening operations and significantly improving assembly productivity.
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 cost-effective, modular, and reliable cell contact arrangement that maintains secure connections without play, accommodating thermal expansion and stress, thus ensuring efficient and reliable electrical connections within energy storage modules.
Implementation Method 1
the snap spring allows limited movement of the cell connector. This is necessary, for example, when welding the cell connector to the connection terminals, since the cell connector expands due to heating.
Implementation Method 2
the cell connector expands due to heating. During operation of the energy storage module, too, the cell connector can heat up and thus the cell connector can expand.
Implementation Method 3
the cell connectors are in the correct place and can be directly connected to the connection terminals of the storage cells, in particular welded or soldered.
Implementation Method 4
the cell connectors are in the correct place and can be directly connected to the connection terminals of the storage cells, in particular welded or soldered.
Implementation Method 5
the connecting arc allows a certain movement or length expansion of the cell connector in the third direction 21.
Data Source
AI summary
The invention relates to a cell contacting arrangement (8) for an energy storage module (1) having a plurality of electrochemical storage cells (2), each storage cell (2) having at least two electric connection terminals (3, 4). Said arrangement comprises: a carrier plate (9) which can be placed on the energy storage module (1), and at least one cell connector (10) inserted into the carrier plate (9) for connecting the at least two of the connection terminals (3, 4) of different storage cells (2). The carrier plate (9) comprises at least one catch spring (11) having a detent (12) for fixing the cell connector (10) in the carrier plate (9).