Multi-section Battery Cell Connector with Insulating Sections
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Solution Overview
Problem
Existing cell connectors require a large number of components to electrically connect battery cells, complicating the process and increasing the risk of errors in interconnection.
Innovation Solution
A cell connector with alternating electrically conductive and insulating sections, made from metallic and plastic materials respectively, is designed to connect multiple battery cell terminals using a laser welding and clinching process, reducing the number of connectors needed and simplifying the interconnection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cell connectors are used to electrically connect battery cells, then reliable electrical contact is achieved, but a large number of connectors are required which complicates the interconnection process
Solution Approach 1:
Multiple separate cell connectors are merged into a single multi-section connector that can simultaneously connect multiple battery cell terminals. The connector comprises several conductive sections (5, 6) arranged in series, where each section can contact a different terminal, thereby reducing the total number of connectors from multiple individual units to one integrated component.
Solution Approach 2:
The single cell connector is segmented into multiple conductive sections (5, 6) with different material properties. Each section is optimized for contacting specific terminal types (e.g., aluminum sections for aluminum terminals, copper sections for copper terminals), allowing the connector to handle diverse terminal materials while maintaining reliable electrical contact across all connections.
2Reliability
If multiple cell connectors are used to connect all battery cell terminals, then complete electrical interconnection is achieved, but handling and assembly become more difficult
Solution Approach 1:
The handling and assembly operations are merged into a single process by using one multi-section connector instead of multiple separate connectors. The connector can be installed in a single operation, reducing assembly steps and minimizing the risk of errors that could occur during multiple separate connection operations.
Solution Approach 2:
The cell connector is designed with multi-functionality to perform multiple connection tasks simultaneously. Different sections of the connector can contact terminals of different materials and configurations, allowing a single connector design to universalize the connection process across various battery cell arrangements and terminal types.
3Reliability
If cell connectors connect all cell terminals electrically conductively, then maximum electrical connectivity is achieved, but insulation between terminals cannot be provided
Solution Approach 1:
The connector incorporates both conductive and insulating sections with locally differentiated properties. Conductive sections (5, 6) made of electrically conductive materials provide electrical connection where needed, while insulating sections (7) made of electrically insulating materials provide isolation where required. This local differentiation of material properties allows the single connector to simultaneously achieve both electrical connectivity and insulation functions.
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 design allows for efficient and error-reduced electrical connection of battery cells, using fewer connectors and ensuring correct terminal connections, thereby simplifying the formation of battery modules.
Implementation Method 1
a first number of cell terminals being connected by means of a cell connector
Implementation Method 2
a first number of first sections being made of an electrically conductive metallic material
Data Source
Figure 1a~1b
Figure 2
AI summary
The present invention relates to a cell connector (1) for making electrically conductive contact with a plurality of battery cell terminals (2), wherein the cell connector (1) has a plurality of sections (5, 6, 7) which are arranged against one another. In this case, a first number of first sections (5, 6) is composed of an electrically conductive metal material, and a second number of second sections (7) is composed of an electrically insulating plastic, wherein at least one second section (7) is arranged between at least two first sections (5, 6) in each case. The present invention further relates to a method for producing a cell connector according to the invention, wherein the at least one second section (7) is connected to the at least two first sections (5, 6) by means of a nano-moulding method. The present invention furthermore relates to a battery module (4) having a plurality of battery cells (3) which are electrically interconnected with one another, wherein the battery cells (3) each have at least one cell terminal (2), which is electrically conductively connected to an electrode of the battery cell (3), for making electrically conductive contact with the battery cells (3), and wherein at least a first number of cell terminals (2) is connected by means of a cell connector (1) according to the invention.