EV Battery Current Communication Device with Bent Tapered Transition
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Solution Overview
Problem
Current communication devices for electric vehicle batteries face challenges in balancing packaging with ease of manufacturing, particularly in securely connecting bus bars to battery cells while maintaining efficient current communication.
Innovation Solution
A current communication device with a terminal landing and a transition that is both bent and tapered, allowing secure attachment to a bus bar and extending to a current collector, optimizing current flow through a ratio of widths from 2.19 to 3.23, and positioned in a way that minimizes material usage and packaging space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the current communication device uses a traditional design with separate components for connecting bus bars to battery cells, then the ease of manufacture is improved, but the packaging efficiency and material usage increase
Solution Approach 1:
The patent merges the terminal landing and transition portions into a single integrated current communication device. The terminal landing is directly formed as part of the same component as the transition portion, eliminating the need for separate parts and reducing overall material usage while maintaining manufacturing feasibility through continuous forming processes
2Loss of substance
If the current communication device uses a compact design to reduce packaging space, then the material footprint is reduced, but the manufacturing complexity increases
Solution Approach 1:
The transition portion incorporates a bent configuration with specific curvature to achieve compact packaging. The bend allows the transition to navigate around obstacles and fit within constrained spaces while maintaining structural integrity. The curvature is designed with appropriate radii to avoid sharp bends that would complicate manufacturing, balancing compactness with manufacturability
Solution Approach 2:
The transition portion utilizes three-dimensional spatial arrangement to achieve compact packaging. By bending the transition in multiple dimensions and positioning it strategically between the terminal landing and current collector, the design accomplishes space optimization without requiring additional components or complex assembly steps
3Volume of moving object
If the current communication device uses sharp bends to achieve compact packaging, then the packaging efficiency improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent deliberately avoids sharp bends in the transition portion and instead uses gradual curves with specified minimum radii. This approach reduces stress concentrations and manufacturing difficulties while still achieving compact packaging. The curved transitions are designed to flow smoothly between straight sections, maintaining structural integrity and easing fabrication requirements
4Loss of substance
If the current communication device uses a single piece design to reduce material usage, then the material footprint is reduced, but the adaptability to different orientations decreases
Solution Approach 1:
The bent transition portion is designed with flexible geometry that can accommodate various orientations and configurations. The curved sections allow the single-piece device to adapt to different spatial arrangements between battery cells and bus bars, providing versatility in installation while maintaining the material savings of a monolithic design
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 enables efficient current communication with a reduced material footprint, capable current carrying capacity, and potential weight or cost reduction by accommodating different orientations and orientations through a single piece design with minimal sharp bends.
Implementation Method 1
The transition extends from the terminal landing to the current collector... capable current carrying capacity
Implementation Method 2
The terminal landing is welded to the bus bar
Data Source
AI summary
An example electric vehicle battery current communication device includes a terminal landing and a transition from the terminal landing having an area that is both bent and tapered. The transition can bend toward an interior of a battery cell such that a portion of the transition is closer to the interior than each portion of the terminal landing. The terminal landing can attach to a bus bar. The terminal landing can also weld to a bus bar. The transition can extend from the terminal landing to a current collector extending into an interior of the battery cell.