Comb-Shaped Cell Contacting for Fast Battery Module Assembly
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Solution Overview
Problem
Current energy storage modules for vehicles, particularly starter batteries, face challenges in achieving a balance between weight reduction, energy density, reliability, and cost-effectiveness, especially in large-scale series production, due to the limitations of lead accumulators and the complexity of assembly processes.
Innovation Solution
The design of an energy storage module featuring a stacked arrangement of lithium-ion cells with perpendicular flat connection lugs and a comb-shaped contacting device allows for efficient and reliable electrical connections, enabling quick assembly and modular production by facilitating parallel or series connections without the need for pre-assembly of pouch cells, using a modular contacting device with busbars and carriers made from different materials to simplify the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium-ion cells are used instead of lead accumulators, then energy density and service life are improved, but weight and production complexity increase
Solution Approach 1:
The battery system is divided into modular cell packs, each containing multiple lithium-ion cells arranged in a standardized stacked formation. This segmentation allows for simplified production of individual modules that can be assembled into complete battery systems, reducing overall production complexity while maintaining high energy density benefits
Solution Approach 2:
The contacting device is designed with a universal comb-shaped structure that can accommodate different cell configurations and connection lug arrangements. This multi-functional design allows the same basic contacting device to work with various cell types and pack arrangements, simplifying production processes across different battery applications
2Productivity
If cells are arranged in stacked formation with perpendicular connection lugs, then assembly speed is improved, but contact reliability may be compromised
Solution Approach 1:
The comb-shaped contacting device acts as an intermediary component that bridges the perpendicular connection lugs of adjacent cells. The multiple teeth of the comb structure simultaneously engage with connection lugs from different cells, creating reliable electrical contacts while maintaining the space-efficient perpendicular arrangement that enables fast assembly
Solution Approach 2:
The connection lugs of adjacent cells are positioned to nest between the teeth of the comb-shaped contacting device. This nested arrangement allows multiple electrical connections to be made simultaneously within a compact space, ensuring contact reliability while maintaining the perpendicular stacked configuration for rapid assembly
3Device complexity
If comb-shaped contacting device is used, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The contacting device is segmented into multiple identical teeth, each performing the same function of engaging with connection lugs. This standardization of individual components simplifies the overall device design and manufacturing, as each tooth can be produced using the same process and then assembled into the complete comb structure
Solution Approach 2:
The comb-shaped contacting device uses standardized dimensional parameters for its teeth, including uniform spacing, width, and engagement depth. These standardized parameters enable the use of precision manufacturing processes that can consistently produce the required alignment accuracy, reducing the burden on individual tooth fabrication while maintaining overall device precision
Data Source
AI summary
An energy storage module comprising a plurality of electrochemical cells for storing electric energy and comprising at least one contacting device for electrically contacting the plurality of electrochemical cells. Each of the electrochemical cells has a first flat connection lug for contacting a first electrode of the respective electrochemical cell and a second flat connection lug for contacting a second electrode of the respective electrochemical cell. The electrochemical cells are arranged in a stacked formation and form a cell pack such that the first and second flat connection lugs extend outwards from two opposing sides of the cell pack in an at least substantially perpendicular manner. According to the invention, the at least one contacting device is substantially comb-shaped in particular and has a plurality of teeth which are formed and arranged such that a first or second connection lug is or can be received between two adjacent teeth.