Integrated Contact Element for Battery Thermal and Electrical Management

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Solution Overview

Problem

Traction batteries in vehicles face high costs and complexity due to the need for multiple components for mechanical, thermal, and electrical contacting, which increases weight, material usage, and assembly complexity, while also complicating recycling and maintenance.

Innovation Solution

A contact element that is partially electrically and thermally conductive, designed for force-fit, form-lock, or integral joints, allowing for single-component mechanical, thermal, and electrical contacting of energy stores, reducing the number of components needed and simplifying assembly and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate components are used for mechanical, thermal, and electrical contacting of energy stores, then reliable contacting is achieved, but system weight, material usage, and device complexity increase

Engineering Contradiction:

Improvecontacting reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines mechanical support, thermal management, and electrical connection functions into a single integrated contact element. This element simultaneously provides structural support for the energy store, conducts heat away through thermally conductive portions, and establishes electrical contact through electrically conductive portions, thereby reducing the number of components while maintaining all necessary functions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The contact element is designed as a multi-functional component that performs multiple roles: it serves as a mechanical support structure, a thermal management interface, and an electrical connection point. This universal design allows one component to replace what would traditionally require multiple separate parts, reducing overall system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If multiple separate components are used for mechanical, thermal, and electrical contacting, then functional requirements are met, but assembly complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidassembly steps

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

By integrating multiple functions into a single contact element, the patent reduces the number of assembly steps required. Instead of separately installing mechanical supports, thermal management components, and electrical connections, all functions are achieved through one component that can be installed in a single operation, thereby simplifying the manufacturing process

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If multiple components are used for contacting energy stores, then comprehensive contacting is achieved, but system weight and material usage increase

Engineering Contradiction:

Improvecontacting completenessVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent eliminates the need for multiple separate components by using a single integrated contact element that performs mechanical support, thermal management, and electrical connection functions simultaneously. This consolidation reduces the total material required and consequently decreases system weight while maintaining all necessary contacting functions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multi-functional contact element achieves comprehensive contacting capabilities without requiring multiple specialized components. By designing one element that can handle mechanical loads, conduct heat, and transmit electrical current, the patent reduces overall material usage and system weight compared to traditional multi-component approaches

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 decreases system weight and material usage, simplifies assembly and maintenance, and facilitates recycling by providing a single component for complete contacting, enhancing the integration of battery components and reducing costs.

Implementation Method 1

the contact element being at least partially thermally conductive... bringing the contact element in contact with the energy store in such a way that the heat generated by the energy store during operation may be dissipated, in particular completely, via the contact element

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the contact element being at least partially electrically conductive... electrically connecting the energy store to the contact element, and thus in particular moreover a potential electrical connection to an electrical system

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS9543686B2Contact element for mechanically, thermally and electrically contacting an energy store

Publication Date: 2017.01.10 ROBERT BOSCH GMBH

AI summary

A contact element for mechanically, thermally and electrically contacting at least one energy store at least partially delimits at least one accommodating space for accommodating the at least one energy store. The contact element is designed for a force-fit, form-locked and/or integral joint with at least one subarea of the energy store, the contact element being at least partially electrically conductive, and the contact element being at least partially thermally conductive.