Flexible Voltage Taps for Energy Storage Module Rewiring
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Solution Overview
Problem
Existing energy storage module rewiring elements face challenges in efficiently compensating for static and dynamic displacements between storage cells, leading to potential connection breaks and increased production costs due to mechanical loads and tolerances in cell terminal alignment.
Innovation Solution
The energy storage module rewiring element features a conductor track structure with flexible voltage taps that have angled connection sections and grooves, allowing for movement compensation and absorption of mechanical loads, enabling a cost-effective and compact design with improved flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid cell connectors are used to establish electrical connections between storage cells, then electrical connectivity is ensured, but the connectors are subjected to excessive mechanical loads and forces due to static and dynamic displacements, leading to potential connection breaks
Solution Approach 1:
The patent applies this principle by using a flexible connecting part with integrated temperature monitoring capability. The flexible design allows the connector to accommodate static and dynamic displacements between storage cells without exceeding permissible forces and moments, while the integrated temperature monitoring ensures reliable operation. This resolves the contradiction by making the connector flexible rather than rigid, preventing connection breaks while maintaining electrical connectivity.
Solution Approach 2:
The patent applies this principle by designing the connecting part to be flexible rather than rigid, enabling it to dynamically adapt to displacements and dimensional changes of storage cells during operation. The flexible connecting part can deform to accommodate movement while maintaining electrical contact, and the temperature monitoring capability provides real-time feedback for reliable operation under varying conditions.
2Adaptability or versatility
If flexible connecting parts are used to compensate for displacements, then movement compensation is achieved, but the production complexity and cost increase due to the need for integrated temperature monitoring and flexible structure fabrication
Solution Approach 1:
The patent applies this principle by merging the temperature monitoring function directly into the flexible connecting part. The temperature monitoring capability is integrated into the connector itself rather than being a separate component, which reduces the overall number of parts and simplifies assembly. This integration maintains movement compensation capability while reducing production complexity compared to using separate monitoring and connecting components.
Solution Approach 2:
The patent applies this principle by designing the flexible connecting part to serve multiple functions simultaneously: it provides mechanical connection, accommodates displacements through flexibility, and includes integrated temperature monitoring. This multi-functionality reduces the need for separate components, thereby reducing device complexity and production costs while maintaining adaptability to movements.
3Reliability
If precise alignment of cell terminals is ensured through tight tolerances, then connection reliability is improved, but production costs increase due to the need for high-precision manufacturing processes
Solution Approach 1:
The patent applies this principle by using a flexible connecting part that can accommodate misalignments and displacements between cell terminals. Instead of requiring tight tolerances for precise alignment, the flexible connector absorbs the dimensional variations through its deformability. This significantly reduces manufacturing costs by allowing broader tolerances while maintaining connection reliability.
Solution Approach 2:
The patent applies this principle by changing the mechanical properties of the connecting part to be flexible rather than rigid. This parameter change allows the connector to adapt to dimensional variations in cell terminals without requiring high-precision manufacturing. The flexibility parameter enables the system to tolerate larger tolerances while maintaining reliable electrical connections.
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 solution effectively compensates for static and dynamic movements, preventing connection breaks and reducing production costs by allowing for automatic and reliable electrical connections between cell connectors, ensuring the stability and longevity of the energy storage module.
Implementation Method 1
the voltage taps are designed as a flexible movement compensation element to compensate for a relative movement of the energy storage module rewiring element with respect to the cell connectors and/or different expansions of the energy storage module rewiring element and the cell connectors during operation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a rewiring element (1) for an energy storage module (100), which comprises a plurality of storage cells (110), which are arranged one over the other in at least one vertical series and which are electrically connected to each other in pairs by means of cell connectors (120). The rewiring element (1) according to the invention comprises a conducting track structure (10) having a plurality of conducting tracks (11), which are arranged next to each other and which extend vertically, and having a plurality of voltage taps (20), the first ends (21) of which, facing the conductor tracks (11), are each connected to an associated first end (12) of a respective conductor track (11), and the free, second ends (22) of which are provided for bonded connection to associated cell connectors (120). The voltage taps (20) for compensating a relative motion of the rewiring element (1) with respect to the cell connectors (120) and/or different expansions of the rewiring element (1) and of the cell connectors (120) are designed as motion-compensating elements.