Snap-Fit Cell Connector Support for Tolerance-Stable Battery Modules
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Solution Overview
Problem
Existing electromechanical cell-contacting devices for battery modules in hybrid or electric vehicles face challenges in ensuring secure electrical connectivity amidst manufacturing tolerances, vibrations, and varying distances between storage-cell modules, while also requiring ease of assembly and cost-effectiveness.
Innovation Solution
A cell-contacting device with a mechanical cell-connector support and snap-fit arranged cell-connector sheets that allow form-fitting installation, compensating for position tolerances and securing the sheets during transportation, using a locking mechanism with spring-loadable latching mechanisms and rigid latching devices for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used to fix contact elements to the support structure, then mechanical strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a snap-fit mechanical locking system. The contact element features a locking projection that engages with a corresponding recess in the support structure, eliminating the need for welding operations while maintaining secure mechanical attachment. This substitution simplifies manufacturing by removing complex welding equipment and processes.
Solution Approach 2:
The patent changes the attachment mechanism from permanent welding to reversible snap-fit connection. The contact element is designed with elastic deformation capabilities, allowing it to be inserted and locked into place mechanically. This parameter change from thermal-structural bonding to elastic-mechanical bonding reduces manufacturing complexity while maintaining sufficient connection strength.
2Stability of the object's composition
If rigid fixed connections are used for contact elements, then structural stability is improved, but adaptability to position tolerances and thermal changes deteriorates
Solution Approach 1:
The patent introduces dynamic adaptability through the snap-fit mechanism that allows controlled movement. The contact element can be inserted at slightly different positions and will lock into place, accommodating position tolerances. The elastic properties of the contact element allow it to deform slightly and adapt to thermal expansion and contraction, maintaining electrical contact while preserving overall structural stability.
Solution Approach 2:
The patent changes the connection from rigid fixed to semi-rigid snap-fit with controlled flexibility. The locking mechanism provides sufficient structural stability for mechanical support while allowing limited movement to accommodate thermal expansion and position variations. This parameter change enables the system to adapt to environmental changes without compromising structural integrity.
3Reliability
If complex locking mechanisms are used to secure contact elements, then reliability of electrical connection is improved, but ease of assembly deteriorates
Solution Approach 1:
The patent segments the locking function into simple geometric features: a projection on the contact element and a corresponding recess in the support structure. This segmentation creates a self-aligning, self-locking mechanism that is both reliable and simple to assemble. The divided functional elements (projection and recess) work together to provide secure attachment without complex mechanisms.
Solution Approach 2:
The snap-fit mechanism is designed to be self-locking and self-aligning. When the contact element is inserted, the projection automatically engages with the recess, providing reliable electrical connection without requiring additional fastening operations. The design serves itself by incorporating the locking function directly into the basic geometry of the components, eliminating the need for separate locking devices or complex assembly procedures.
4Object-affected harmful factors
If protective components are added to shield contact elements, then protection against harmful factors is improved, but device complexity increases
Solution Approach 1:
The patent merges the protective function with the existing support structure and contact element design. The support structure is configured to provide mechanical protection and positioning, while the snap-fit mechanism itself provides protection by securing the contact element in place. This merging of protective functions into existing components eliminates the need for separate protective covers or shields, maintaining protection against contamination while avoiding additional structural complexity.
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 provides reliable electrical connectivity by adapting to position tolerances and thermal changes, ensuring secure mounting and easy assembly, while maintaining mechanical integrity and reducing production costs.
Implementation Method 1
a relevant cell-connector sheet (300) can be installed on/in the cell-connector support (200) by means of at least one snap-fit arrangement (205) of the cell-connector support (200)
Implementation Method 2
several separately formed electromechanical contact elements (310) for electrically contacting in each case exactly two directly mutually adjacent storage-cell modules (10)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to an electromechanical cell-contacting device (20) for a battery module (1) of a battery (0) of a motor vehicle, in particular for a traction-battery module (1) of a traction battery (0) of a hybrid or electric motor vehicle, wherein the cell-contacting device (20) comprises a mechanical cell-connector support (200) which can be fitted onto storage-cell modules (10) of the battery module (1) and at least one electromechanical cell-connector sheet (300), and a relevant cell-connector sheet (300) can be mounted or is mounted on/in the cell-connector support (200) by means of at least one snap-fit arrangement (205) of the cell-connector support (200), with the result that the cell-connector sheet (300) can be installed or is installed in sections on/in the cell-connector support (200) in a substantially form-fitting manner.