Polymer Cell Contacting Structure for Flexible Battery Connections
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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 that includes at least one electrical conductor for transporting current and a structural component providing mechanical stability and electrical insulation, where the structural component covers a part of the electrical conductor and is made of a polymer, allowing for easier manufacturing and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex structure with separate carrier and busbars is used, then electrical connections are established, but production costs increase and manufacturing becomes complicated
Solution Approach 1:
The patent combines the carrier and busbar into a single integrated component made of conductive material. This merging eliminates the need for separate production steps for carrier and busbars, reducing manufacturing complexity while maintaining reliable electrical connections between battery cells.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it provides mechanical support as a carrier and establishes electrical connections as a busbar. This multi-functionality reduces the number of components needed and simplifies the overall cell contacting system structure.
2Stability of the object's composition
If a rigid cell contacting system structure is used, then mechanical stability is provided, but flexibility in arranging battery cells is limited
Solution Approach 1:
The patent introduces a flexible membrane as part of the cell contacting system structure. This flexible component allows the system to adapt to different battery cell arrangements and geometries while maintaining mechanical stability through its ability to deform and conform to various configurations.
Solution Approach 2:
The flexible membrane acts as a thin film structure that provides mechanical support while allowing geometric adaptation. This thin film can be molded into different shapes and configurations to accommodate various battery cell arrangements without compromising the structural integrity of the cell contacting system.
3Reliability
If traditional cell contacting systems are used, then electrical connections are established, but the number of possible connections is limited thus limiting voltage and capacity
Solution Approach 1:
The patent divides the cell contacting system into multiple independent contact points and connection paths through the integrated carrier-busbar component. This segmentation allows for multiple electrical connections to be established simultaneously, increasing the number of possible connections and enabling higher voltage and capacity configurations.
Solution Approach 2:
The integrated component design allows for three-dimensional connection paths and multiple connection layers. This dimensional expansion enables more electrical connections to be established within the same space, increasing the overall connectivity and potential voltage/capacity of the battery pack.
4Reliability
If multiple separate components are used for cell contacting, then electrical connections are established, but production costs increase due to separate production steps
Solution Approach 1:
The patent combines the carrier and busbar into a single integrated component that can be produced in one manufacturing step. This merging eliminates the need for separate production steps for carrier and busbars, reducing manufacturing complexity and production costs while maintaining reliable electrical connections.
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
at least one structural component adapted to provide mechanical stability and electrical insulation to said at least one electrical conductor
Data Source
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AI summary
The invention relates to a cell contacting system (1) for electrically contacting a plurality of battery cells (101) of a battery, comprising at least one electrical conductor (2) for transporting electric current from and/or to one or more battery cells, and at least one structural component (3) adapted to provide mechanical stability and electrical insulation to said at least one electrical conductor, wherein said at least one structural component covers a part, "covered part" (4), of said at least one electrical conductor and comprises at least one polymer.