Flat Cell Connector with Resilient Conductor Track
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Solution Overview
Problem
Existing cell connectors face challenges in maintaining a compact design while compensating for position and assembly tolerances, as well as movements of cell terminals during charging and discharging, without applying excessive forces, and they often suffer from increased electrical resistance and heat generation due to current flow.
Innovation Solution
A cell connector with a conductor track that runs entirely in one plane, featuring a resilient conductor path made of multiple metallic layers or a flat metal sheet, which compensates for positional changes and assembly tolerances, and can be designed as a stepped band or meandering shape to enhance elasticity and current-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cell connector is designed to be flat and compact, then the overall device size is reduced, but the ability to compensate for position and assembly tolerances deteriorates
Solution Approach 1:
The conductor track is designed with resilient sections that can dynamically deform to accommodate position and assembly tolerances. The conductor track includes straight sections for electrical connection and resilient sections with reduced cross-sections that can elastically deform, allowing the connector to adapt to manufacturing variations while maintaining a compact flat structure.
Solution Approach 2:
The cross-sectional parameters of the conductor track are varied along its length. Straight sections have larger cross-sections for optimal electrical conductivity, while resilient sections have reduced cross-sections to increase flexibility and tolerance compensation capability. This parameter variation allows the single-piece connector to achieve both compactness and adaptability.
2Adaptability or versatility
If the conductor path is made resilient to compensate for movements, then tolerance compensation improves, but electrical resistance increases
Solution Approach 1:
The conductor track is segmented into functionally distinct sections: straight sections with larger cross-sections for low-resistance electrical connection, and resilient sections with reduced cross-sections for movement compensation. This segmentation allows each section to be optimized for its specific function while maintaining overall electrical reliability.
Solution Approach 2:
Different sections of the conductor track have different local qualities - straight sections have larger cross-sections optimized for electrical conductivity, while resilient sections have smaller cross-sections optimized for flexibility. This local quality variation enables the conductor track to simultaneously achieve low electrical resistance and high movement compensation capability.
3Power
If multiple metallic layers are used to increase current-carrying capacity, then electrical performance improves, but device complexity increases
Solution Approach 1:
Multiple metallic layers are merged into a single integrated conductor track component. The conductor track includes first and second metallic layers that are substantially interconnected, forming a unified structure that provides enhanced current-carrying capacity without requiring separate assembly steps or additional fastening elements.
Solution Approach 2:
The conductor track is formed as a composite structure with multiple metallic layers. This composite construction increases the effective cross-sectional area for current flow, thereby enhancing current-carrying capacity while maintaining the simplicity of a single-piece formed component that requires no additional assembly.
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 design allows for a compact, efficient energy storage device with reduced mechanical stress and minimal heat generation, enabling flexible movement of cell terminals and maintaining high current-carrying capacity.
Implementation Method 1
a resilient conductor path made of multiple metallic layers or a flat metal sheet, which compensates for positional changes and assembly tolerances
Data Source
Figure 1~4
Figure 5~8
Figure 9~11
AI summary
The invention relates to a cell connector (2a-k) for the electrical connection of cell terminals (4) of an energy storage device, comprising contact elements (6a-k) for connection with at least one cell terminal (4) each, and a compensating element (10a-k) electrically connecting two contact elements (6a-k) with at least one resilient conductor track (12a-k). A compact cell connector (2a-k) is achieved by having the conductor track (12a-k) run completely in one plane with the two contact elements (6a-k).