Flexible Conductor for Battery Cell Connector Vibration Resistance
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Solution Overview
Problem
Existing battery systems face challenges in maintaining a reliable and automated electrically conductive connection between cell connectors and electronic units, particularly under vibration and agitation, which can lead to increased transition resistance and measurement errors, especially in lithium-ion cells.
Innovation Solution
A battery system design featuring a conductor with flexible sections and contact elements, where the first pin is fixedly connected to the cell connector and the second pin to the electronic unit, utilizing crimp connections or welding to ensure a durable and automated connection, and conical sleeves for simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solder connection is used to connect the conductor to the cell connector and electronic unit, then the electrical connection is established, but the transition resistance increases or the connection separates due to vibrations and agitations during operation
Solution Approach 1:
The patent changes the connection method from soldering to crimping, fundamentally altering the physical and mechanical parameters of the joint. The crimp connection creates a cold-welded, mechanically interlocked structure that is insensitive to vibrations and temperature cycles, eliminating the harmful effects that plague solder joints in automotive battery applications.
Solution Approach 2:
The patent replaces the thermal-chemical bonding mechanism of soldering with a purely mechanical crimping process. The crimp connection uses controlled deformation of the conductor and contact element to create a permanent, vibration-resistant mechanical interlock, substituting the fragile thermal field of soldering with a robust mechanical field.
2Stability of the object's composition
If a rigid conductor is used to connect the cell connector and electronic unit, then the electrical connection is stable, but the connection is sensitive to vibrations and agitations
Solution Approach 1:
The patent introduces a flexible section with a specific geometry into the conductor, transforming it from a rigid structure to a semi-flexible one. This flexible section can deform elastically under vibration and agitation loads, absorbing mechanical energy and preventing stress transmission to the crimp connections, thereby maintaining connection stability while tolerating dynamic environmental conditions.
3Manufacturing precision
If manual assembly methods are used to create the electrical connection, then the connection quality can be controlled, but the automation level is low and productivity is reduced
Solution Approach 1:
The patent segments the conductor into distinct functional sections: rigid connection sections for stable electrical contact, a flexible section for vibration absorption, and crimpable ends for automated mechanical joining. This segmentation allows each section to be optimized for its specific function and enables the entire assembly to be processed through automated crimping machines, achieving both high precision and full automation.
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 high degree of process safety and reliability, enhancing tolerance to vibrations and agitations, ensuring stable voltage detection and reducing the risk of connection failure.
Implementation Method 1
a conductor (3) having at least one flexible section (7) and which facilitates an electrically conductive connection between the first pin (5.1) and the second pin (5.2)
Implementation Method 2
utilizing crimp connections or welding to ensure a durable and automated connection
Implementation Method 3
utilizing crimp connections or welding to ensure a durable and automated connection
Data Source
AI summary
A battery system and a method for producing an electrically conductive connection in a battery system. The battery system includes a plurality of cells arranged in at least one stack, a cell connector to connect a pole of a first cell in an electrically conductive manner to a pole of a second cell, an electronic unit to detect the voltage of the cells, a first pin arranged on the cell connector, at least one second pin arranged on the electronic unit; and a conductor to connect the first pin in an electrically conductive manner to the second pin, the conductor having at least one flexible section, a first contact element connected in an electrically conductive manner to a first end of the flexible section and also to the first pin, and a second contact element connected in an electrically conductive manner to a second end of the flexible section and also to the second pin.