Prismatic Battery Current Collector Bracket for Low-Stress Tab Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for electrically connecting multiple cells in a prismatic battery, such as bending foil tabs at sharp angles, introduce stress and strain that can lead to tears in the foil sheets.
Innovation Solution
A battery cell stack assembly that includes a current collector bracket assembly with arms that align and electrically connect the anode or cathode cell tabs, reducing the need for sharp bending and minimizing stress on the foil sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foil tabs are bent at sharp angles to contact one another for electrical connection, then the cells can be electrically connected, but the foil sheets may tear due to stress and strain
Solution Approach 1:
A current collector bracket assembly is introduced as an intermediary component between the foil tabs of adjacent cells. The bracket includes arms that extend between the cells and make electrical contact with the foil tabs, eliminating the need to bend the tabs at sharp angles. This mediator transfers the electrical connection function from the foil tabs themselves to a dedicated bracket structure, resolving the contradiction between achieving reliable electrical connection and preventing foil sheet damage.
2Ease of manufacture
If foil tabs are bent at sharp angles up to ninety degrees to connect cells, then electrical connection is achieved, but stress and strain are introduced to the foil sheets
Solution Approach 1:
The electrical connection function is segmented from the foil tabs and assigned to a separate current collector bracket assembly. The bracket is divided into multiple arms, each responsible for connecting specific foil tabs. This segmentation allows the connection mechanism to be optimized independently from the foil tab structure, enabling simple assembly without introducing stress to the foil sheets.
3Quantity of substance
If multiple cells are joined together in a prismatic battery, then the battery capacity increases, but the complexity of electrical connections increases
Solution Approach 1:
The current collector bracket assembly is designed as a universal component that can connect multiple foil tabs simultaneously through its multiple arms. Each bracket can serve multiple connection points, and the brackets can be stacked to accommodate different numbers of cells. This multi-functionality reduces the overall complexity of electrical connections as the number of cells increases, since the same bracket design can be reused throughout the battery assembly.
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 proposed solution reduces the stress and strain on the foil sheets by minimizing the angle of bending required for electrical connections, thereby enhancing the reliability and durability of the battery cell stack assembly.
Implementation Method 1
The at least one current collector bracket assembly electrically connects either each of the anode cell tabs with one another or each of the cathode cell tabs with one another
Data Source
AI summary
A battery cell stack assembly for a prismatic battery includes a plurality of monocells and two current collector bracket assemblies. Each monocell includes an anode electrode sheet having an outer perimeter and an anode cell tab and a cathode electrode sheet having a cathode cell tab. One of the current collector bracket assemblies electrically connect each of the anode cell tabs with one another and a remaining current collector bracket assembly electrically connects each of the cathode cell tabs with one another, and each current collect bracket assembly includes at least one arm that is positioned to electrically connect either two or more of the anode cell tabs or two or more of the cathode cell tabs to one another.