Prismatic Battery Block Contact Bridge Design
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Solution Overview
Problem
Existing battery packs face challenges in maintaining reliable electrical connections under mechanical and thermal influences due to relative movements of battery cells caused by volume changes, leading to undefined spring forces and potential disconnection.
Innovation Solution
The design incorporates a contact bridge with a pole section and contact plate connected via elastic contact arms, allowing for relative movement compensation, and a swelling sealing tape to secure battery cells within a housing, ensuring stable mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery cells are securely fixed mechanically to prevent movement under external forces and vibrations, then mechanical stability is improved, but the cells cannot accommodate volume changes during electrical operation, leading to high mechanical forces on connection poles
Solution Approach 1:
The contact bridge is designed with a dynamic pole opening that can expand and contract to accommodate volume changes of battery cells during operation. The pole opening is formed with a larger diameter than the pole section, creating a gap that allows the pole section to move dynamically within the opening, thereby absorbing expansion forces without transmitting them to the connection pole.
Solution Approach 2:
The contact bridge utilizes elastic deformation of its material to accommodate dimensional changes. The contact arms are made of elastic material that can deform to maintain electrical contact while allowing the pole section to move within the pole opening, thus adapting to volume changes of the battery cells without compromising mechanical stability.
2Reliability
If battery cells are allowed sufficient free space to accommodate volume changes during operation, then electrical operation reliability is improved, but mechanical stability under external forces and vibrations deteriorates
Solution Approach 1:
The contact bridge is segmented into a rigid housing structure and a flexible contact element (pole section with contact arms). The housing provides mechanical stability and secure fixation of battery cells, while the contact element with its elastic material and gap design provides the necessary compliance to accommodate volume changes during electrical operation.
3Reliability
If a helical spring contact element is used to maintain contact force, then electrical contact is maintained, but the spring force becomes undefined under mechanical and thermal influences, preventing secure permanent contact
Solution Approach 1:
An intermediate element in the form of a gel cushion is introduced between the contact bridge and the connection pole. This gel intermediary provides both mechanical compliance to accommodate dimensional changes and thermal management, while maintaining consistent electrical contact without relying on spring force that varies with temperature and mechanical stress.
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 ensures reliable electrical contact and mechanical stability by accommodating volume changes and vibrations, preventing high mechanical forces on connection poles and maintaining secure connections under varying conditions.
Implementation Method 1
The contact arm, which is advantageously made of an elastically resilient material, expediently has an elastically resilient shape, in particular an approximately S-shaped course, the elasticity of the electrically conductive material of the contact plate with the contact arms being sufficient to elastically intercept the relative movements that occur
Implementation Method 2
an appropriate intermediate element is inserted, which reduces friction. This intermediate element is preferably a heat-transferring element, in particular a gel cushion, as a result of which a tight connection between the contact bridge and the connection pole of the battery cell that transfers heat well is achieved
Implementation Method 3
This intermediate element is preferably a heat-transferring element, in particular a gel cushion, as a result of which a tight connection between the contact bridge and the connection pole of the battery cell that transfers heat well is achieved
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a rechargeable battery block comprising a large number of individual rechargeable battery cells (3) which are arranged in a common housing (2). Each rechargeable battery cell (3) has a positive and a negative connection pole (4, 6), wherein the connection poles (4, 6), which are to be electrically connected to one another, are connected to one another by means of a contact bridge (10). In order to allow for a relative movement between the connection poles and the contact bridge, provision is made for a pole section (8) of a connection pole (4, 6) to project into a pole opening (18) in the contact bridge (10), wherein play (s) is created between the pole section (8) and the wall (16) of the pole opening (18). The free end (17) of the pole section (8) is electrically conductively connected to a contact plate (20), wherein the contact plate (20) is electrically conductively fixed to the contact bridge (10) by way of at least one contact arm (22), wherein the contact arm (22) bridges the gap (15) between the pole section (8) and the contact bridge (10).