Prismatic Cell Metal Contact Pin for Sensor Wiring
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Solution Overview
Problem
High-capacity battery systems face challenges in robust and efficient electrical connections for sensor and instrument line integration, leading to complex and lengthy cable harnesses, which can result in short-circuits and increased construction complexity.
Innovation Solution
A prismatic accumulator cell with a cuboid housing and electrodes, featuring a metal contact pin electrically connected to one of the electrodes and routed through an insulating material cladding, provides a robust and simplified connection method using a stamped bent metal contact pin, reducing the complexity and length of cable harnesses and enhancing electrical bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If instrument lines and sensors are connected to cell connectors by means of plug-in, soldered or crimped connections, then electrical connection for measurement is achieved, but the cable harness becomes complex and lengthy, increasing the risk of short-circuits and construction complexity
Solution Approach 1:
The patent extracts the measurement connection function from the cell connector and relocates it to the cell housing. By providing metal contact pins directly in the housing that are electrically connected to the electrodes, the instrument lines and sensors can be connected directly at the cell level without requiring complex cable harnesses routed through cell connectors, thereby simplifying the overall electrical architecture while maintaining reliable electrical connections for temperature and voltage measurements
2Ease of operation
If cell connectors are used for all electrical connections including sensors and instrument lines, then a unified connection point is provided, but the cable harness length and complexity increase, leading to more potential short-circuit points
Solution Approach 1:
The patent segments the electrical connection functions by providing separate connection points: terminal connections for energy transfer through cell connectors, and metal contact pins for measurement connections directly in the housing. This segmentation allows measurement instrument lines to be routed independently and directly to the cell, reducing cable harness complexity and minimizing potential short-circuit points between power and measurement circuits
3Adaptability or versatility
If multiple connection points are provided on the cell connector for sensors and instrument lines, then comprehensive measurement capability is achieved, but the construction complexity and cable harness requirements increase
Solution Approach 1:
The patent combines the measurement connection function with the cell housing structure itself. By integrating metal contact pins directly into the housing that are electrically connected to the electrodes, the housing serves dual purposes: mechanical protection and electrical connection for measurements. This merging eliminates the need for separate connection points on cell connectors for sensors, reducing construction complexity while maintaining comprehensive measurement capability through direct pin connections
Data Source
AI summary
A prismatic accumulator cell (2) with a cuboid housing (4) and electrodes (10) arranged therein, wherein the electrodes (10) for the take-up and delivery of energy from the accumulator cell (2) are electrically connected to terminal connections (18), wherein the housing (4) is provided with a cover area (24) which accommodates the terminal connections (18) and at least one area provided with an insulating material cladding (26). The accumulator cell (2) is provided with at least one metal contact pin (28), which is electrically connected to one of the two electrodes (10), and is routed through the insulating material cladding (26).