Magnetic Battery Stack Contact Assembly for Faster Cell Monitoring
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Solution Overview
Problem
The assembly of detection devices on large battery stacks is labor-intensive and costly due to the need for individual connections between each battery level and the detection device.
Innovation Solution
A detection device with a flexibly designed contact element and a magnetic element for magnetic fixation to the counter-contact section of the battery cell, allowing for simplified alignment and secure attachment without complex fastening methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual connections are manufactured for each battery level in large battery stacks, then reliable electrical connection is achieved, but manufacturing cost and assembly time increase significantly
Solution Approach 1:
The patent combines multiple contact elements into a single integrated contact device that can simultaneously establish electrical connections with multiple battery levels. The contact device includes a support structure with multiple contact elements arranged to contact different battery levels, allowing one-component mounting rather than individual connections for each level.
Solution Approach 2:
The contact device is designed as a universal component that can be applied to battery stacks with different numbers of battery levels. The support structure and contact elements are configured to accommodate various battery stack configurations, enabling the same device to perform multiple connection functions across different applications.
2Reliability
If material connections are made for each contact element to battery cells, then secure electrical connection is ensured, but labor expenditure and manufacturing complexity increase
Solution Approach 1:
The patent integrates multiple contact elements onto a single support structure, allowing them to be mounted and connected as one unit rather than individually. This merging reduces the number of separate manufacturing steps and labor operations required while maintaining secure electrical connections through the integrated design.
Solution Approach 2:
The contact device is segmented into modular contact elements that can be independently designed and positioned on the support structure. This segmentation allows for flexible configuration to match different battery stack layouts while maintaining the ability to manufacture and assemble the device as a unified component.
3Reliability
If multiple contact elements are arranged on a carrier extending over battery levels, then comprehensive monitoring is achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple contact elements and their mounting functions into a single integrated contact device with a unified support structure. This merging simplifies assembly by reducing the number of separate components that need to be positioned and secured, while the support structure ensures comprehensive monitoring coverage across all battery levels.
Solution Approach 2:
The support structure acts as an intermediary element that holds and positions the contact elements in the correct spatial arrangement. This intermediary structure simplifies the overall assembly process by providing a pre-configured framework that ensures proper positioning and electrical connections without requiring complex individual mounting operations for each contact element.
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 significantly simplifies the assembly process, reduces time and costs, and ensures secure and accurate contact with the battery cells, enhancing the reliability of battery stack monitoring.
Implementation Method 1
the contact element has a magnetic element for magnetically fixing the contact section to the mating contact section
Data Source
Figure 1
Figure 2A~2C
Figure 3~4
AI summary
The invention relates to a detection device (1) for detecting at least one battery property of at least one battery cell (70) of a battery plane (60) of a battery stack (50), comprising a carrier (10) having at least one electrical conducting element (11) and at least one contact element (20) having a contact portion (21) for contacting a counter contact portion (71) of the at least one battery cell (70). The contact element (20) has a sensor portion (30) for detecting the at least one battery property of the battery cell (70), and the sensor portion (30) is connected to the at least one conducting element (11) for forwarding the at least one detected battery property in a data-communicating manner. The invention further relates to a battery stack (50), comprising at least one battery plane (60) having at least one battery cell (70), and to a detection device (1). The invention relates to a method for mounting a detection device (1) to a battery stack (50) having at least one battery plane (60) with at least one battery cell (70), wherein the at least one battery cell (70) has a counter contact portion (71).