Molded Cell Contacting Structure for Flexible Battery Cell Layout
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Solution Overview
Problem
Existing cell contacting systems for battery cells in electric vehicles lack flexibility in arranging battery cells, limit the number of electrical connections, and result in high production costs due to complex structures.
Innovation Solution
A cell contacting system comprising electrical conductors and structural components that provide mechanical stability and electrical insulation, where the structural components are partially molded over the electrical conductors using an injection mold, allowing for flexible arrangement and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional cell contacting systems with separate carrier and busbar structures are used, then electrical connections can be established, but the structure becomes complicated resulting in high production costs and limited flexibility
Solution Approach 1:
The patent combines the carrier structure and busbar into a single integrated component. The conductor is directly formed with insulating sections, eliminating the need for separate carrier and busbar parts. This merging reduces structural complexity while maintaining electrical connection functionality and improving flexibility in battery cell arrangement.
Solution Approach 2:
The integrated conductor structure serves multiple functions simultaneously: it provides electrical connection (busbar function), mechanical support (carrier function), and electrical insulation through integrated insulating sections. This multi-functionality reduces the number of components needed and simplifies the overall system structure.
2Ease of manufacture
If traditional cell contacting systems with separate production steps for carrier and busbars are used, then assembly can be performed, but production costs increase due to multiple separate production steps
Solution Approach 1:
The carrier and busbar are merged into a single integrated conductor component that can be manufactured in one production step. The insulating sections are directly formed as part of the conductor structure, eliminating the need for separate production and assembly steps for different components, thereby reducing production costs and improving manufacturing efficiency.
3Power
If more electrical connections are added to increase battery pack voltage and capacity, then power output improves, but the structure becomes more complex and production costs increase
Solution Approach 1:
The integrated conductor structure with flexible insulating sections allows for dynamic adaptation to different connection configurations. The structure can accommodate varying numbers of electrical connections without requiring fundamental redesign, enabling increased battery pack voltage and capacity while maintaining manageable structural complexity.
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 enhances flexibility in arranging battery cells, increases the voltage and capacity of the battery pack, reduces production costs, and ensures reliable operation with improved electrical insulation and mechanical stability.
Implementation Method 1
at least one structural component adapted to provide mechanical stability and electrical insulation to said at least one electrical conductor
Implementation Method 2
said at least one structural component is partially molded over said at least one electrical conductor using an injection mold
Data Source
AI summary
A cell contacting system for electrically contacting a plurality of battery cells of a battery, having at least one electrical conductor for transporting electric current from and/or to one or more battery cells, and at least one structural component adapted to provide mechanical stability and electrical insulation to the at least one electrical conductor, wherein the at least one structural component covers a part, “covered part”, of the at least one electrical conductor and includes at least one polymer.