Insulation Piercing Cell Connector for Battery Systems
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Solution Overview
Problem
Existing cell connectors for battery systems have complex structures that complicate the attachment of measuring lines, requiring soldering, screws, or stripping, which increases time and cost, especially in large systems.
Innovation Solution
The use of insulation displacement terminals with sharp contacts allows for detachable connections of measuring lines without stripping, using methods like soldering, ultrasonic welding, or 'shooting' for quick and reliable electrical and mechanical contact, combined with nickel-coated copper insulation displacement connectors for enhanced conductivity and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional terminal elements are used with clamping or pressing connections, then electrical connection is achieved, but the structure becomes complex and installation time increases
Solution Approach 1:
The terminal element is divided into two separate components: a clamping unit for electrical connection and an insulation displacement connector for measuring line attachment. This segmentation allows each component to be optimized independently, simplifying the overall structure while maintaining reliable electrical connection through the clamping unit.
Solution Approach 2:
The insulation displacement connector acts as an intermediary component between the measuring line and the terminal element. It provides a simplified attachment mechanism that does not require stripping, soldering, or screwing, thereby reducing installation complexity while ensuring reliable electrical connection through the integrated clamping unit.
2Reliability
If traditional connection methods (soldering, screws, stripping) are used, then electrical connection is achieved, but installation time and cost increase
Solution Approach 1:
The insulation displacement connector enables self-service connection by allowing the measuring line core to be pressed directly into the connector without requiring external tools for stripping, soldering, or screwing. The sharp contact points automatically pierce the insulation and establish electrical connection, making the installation process self-contained and significantly faster.
Solution Approach 2:
The traditional mechanical connection methods (screws, clamps) and thermal processes (soldering) are replaced by a mechanical piercing action of sharp contact points that automatically establish electrical connection when the measuring line core is pressed into the insulation displacement connector, eliminating the need for complex tooling and procedures.
3Reliability
If measuring lines are permanently connected to terminal elements, then electrical connection is stable, but adaptability and ease of repair are reduced
Solution Approach 1:
The connection system transitions from a static permanent connection to a dynamic detachable connection. The insulation displacement connector allows the measuring line to be easily attached and detached from the terminal element, providing adaptability for repairs, replacements, or reconfigurations while maintaining stable electrical connection during operation through the secure pressing mechanism.
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 reduces installation time and cost, provides a reliable and gas-tight connection, and allows for automated production, while ensuring a secure and efficient electrical connection between battery cell poles and measuring lines.
Implementation Method 1
the cores of a measuring line can be pressed into the insulation displacement terminals using a special tool without having to strip the insulation from the measuring line beforehand. Due to sharp contacts in the metallic insulation displacement connector, the insulation of the wire is severed and a gas-tight connection is established.
Implementation Method 2
the insulation displacement connector is connected to the cell connector by soldering or ultrasonic welding, for example
Data Source
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AI summary
The cell connector (3) has several battery cells (2) which are electrically conductively connected with each other through a pole (6) of adjacent battery cell. An insulation-piercing terminal (7) is provided for tapping the electric voltage. The insulation-piercing terminal is partially coated with the specific material having nickel and copper. The insulation piercing connector is soldered, ultrasonically welded and is pressed into the cell connector main portion. A measuring conduit (4) is inserted into insulation piercing connector. An independent claim is included for battery system.