Punch-Bent Cell Connector for Round Battery Cells
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Solution Overview
Problem
The assembly and interconnection of battery cells for motor vehicles are complex, requiring reliable electrical contact while minimizing complexity and ensuring high voltage and capacity, with existing methods facing challenges in precise positioning and maintaining contact pressure over time.
Innovation Solution
A cell connector system using punch-bent parts made from conductive materials, featuring contact elements with spring arms and connecting webs for series and parallel connections, along with design enhancements like stiffening beads and spring rings to ensure reliable and simple electrical contact across multiple cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact springs are welded onto parallel plates for each round cell, then electrical connection is achieved, but the manufacturing process becomes very complex and positioning becomes difficult
Solution Approach 1:
The patent merges multiple separate contact springs and parallel plates into a single integrated cell connector component. This connector includes multiple contact elements with spring arms that directly engage with cell terminals, eliminating the need for separate welding operations and simplifying the overall structure while maintaining reliable electrical connection.
Solution Approach 2:
The cell connector is designed as a universal component that simultaneously performs multiple functions: providing electrical connection, maintaining contact pressure through spring arms, and enabling easy assembly/disassembly. This multi-functional design replaces the specialized welding-based contact springs with a single component that achieves all necessary functions.
2Reliability
If multiple separate contact elements are welded together, then electrical connection is established, but production time and manufacturing cost increase
Solution Approach 1:
The patent combines multiple contact elements into a single punch-bent component that can be produced in one manufacturing step. This integrated cell connector eliminates the need for sequential welding operations, allowing for faster production while maintaining reliable electrical connection across all battery cells.
Solution Approach 2:
The cell connector is pre-formed as a complete integrated component through punch-bending processes before assembly. This preliminary formation of the entire connector structure eliminates the need for time-consuming welding operations during battery assembly, significantly improving production speed.
3Reliability
If contact springs are used for each cell, then electrical connection is achieved, but exact positioning of individual contact springs becomes difficult
Solution Approach 1:
The patent integrates multiple contact elements with spring arms into a single rigid connector structure. This unified design ensures that all contact points are precisely positioned relative to each other through the connector's inherent geometry, eliminating positioning errors that would occur with separate, independently placed contact springs.
Solution Approach 2:
The patent changes the manufacturing approach from welding individual contact springs to punch-bending a single integrated connector. This parameter change in the manufacturing process inherently ensures precise positioning of all contact elements through the rigid structure of the connector, eliminating the need for complex positioning operations.
4Reliability
If complex welding processes are used to assemble contact elements, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple contact elements into a single integrated connector that can be manufactured using simple punch-bending processes. This eliminates the need for complex welding operations, reducing manufacturing cost while maintaining reliable electrical connection through the integrated spring arm design.
Solution Approach 2:
The patent replaces the welding-based mechanical system with a punch-bending-based mechanical system. This substitution eliminates the need for complex welding equipment and processes, simplifying manufacturing while achieving the same electrical connection function through mechanically formed spring arms.
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
Enables easy, reliable, and cost-effective electrical connection of battery cells in series and parallel configurations, maintaining contact pressure and reducing resistance, thus ensuring efficient energy supply to motor vehicles.
Implementation Method 1
spring arms for producing a frictional or non-positive or force locking connection to a respective cell cup of the round cells
Implementation Method 2
floor-side contact surface for producing a bonded connection to a respective cell cap of the round cells
Data Source
AI summary
A cell connector for electric-conductively connecting round cells of a battery for a motor vehicle is disclosed. The cell connector includes a plurality of electric-conductive contact elements for connecting two each of the round cells in series connection on the face side. The contact elements are each provided with a floor-side or bottom contact surface for producing an integral connection to a respective cell cap of the round cells, and spring arms for producing a force-fit connection to a respective cell cup of the round cells; a plurality of electric-conductive connection webs which connect the contact elements arranged in groups with one another. The contact elements and the connection webs are produced from a common punch-bent part. A method for producing a battery for a motor vehicle is also disclosed.