Battery Cell Adapter Structure for Easier Tab-to-Post Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The assembly process of battery cells is complicated due to the need to connect the electrode assembly to the electrode post before welding the end cap to the housing, especially when the electrode posts are disposed on the same end cap, restricting positive and negative electrode connections and requiring the electrode assembly to move a long distance during assembly.

Innovation Solution

The battery cell design includes an adapter component with discrete first and second adapter pieces, allowing the first piece to be connected to the electrode post and the second piece to the electrode assembly tab, followed by a conductive connection between them, simplifying the assembly process by reducing the need for pre-connection to the end cap.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electrode assembly is connected to the electrode post on the end cap before welding, then the battery cell structure is completed, but the assembling process becomes complicated

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembling process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The adapter component is divided into a first adapter piece and a second adapter piece that can be assembled separately. The first adapter piece is connected to the electrode post, while the second adapter piece is connected to the tab of the electrode assembly. This segmentation allows the components to be prepared independently before final assembly, reducing the complexity of the overall assembling process while maintaining reliable electrical connection.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If the electrode posts are disposed on the same end cap, then the battery cell structure is compact, but the electrode assembly has to move a long distance during assembly

Engineering Contradiction:

Improvebattery cell compactnessVSAvoidassembly time

Core Design Contradiction:

Volume of moving objectVSLoss of time

Solution Approach 1:

The adapter component acts as an intermediary between the electrode post and the tab of the electrode assembly. By providing connection sections that extend in different directions, the adapter allows the electrode assembly to be positioned closer to the end cap while still achieving proper electrical connection, thereby reducing the movement distance required during assembly while maintaining a compact battery cell structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the first adapter piece and second adapter piece are connected by a conductive structure, then the electrical connection is established, but additional connection steps are required

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The adapter component merges the mechanical connection function and the electrical conduction function into a single integrated structure. The connection sections of the first and second adapter pieces are designed to be conductive, so that when the adapter pieces are mechanically connected, the electrical connection is automatically established without requiring separate connection steps, thereby simplifying the manufacturing process while ensuring reliable electrical connection.

Inventive Principle:

Principle #5Merging (Combining)

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 design simplifies the assembly process by allowing the electrode assembly to be loaded into the housing more easily, reducing the complexity and facilitating connections between the adapter pieces, thereby streamlining the manufacturing process.

Implementation Method 1

the ends of the first adapter piece and the second adapter piece are connected by a conductive structure

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP4181307B1Battery cell, battery, electric device, and method for manufacturing battery cell

Publication Date: 2025.10.22 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

Figure 1~2
Figure 3~5
Figure 6~8

AI summary

This application provides an adapter component, a battery cell, a battery, an electrical device, and a method and device for manufacturing a battery cell. The adapter component includes a first adapter piece and a second adapter piece disposed discretely. The first adapter piece is configured to be connected to one of an electrode post or a tab. The second adapter piece is configured to be connected to the other of the electrode post or the tab. The first adapter piece substantially extends along a first direction. The second adapter piece substantially extends along a second direction. The first direction intersects the second direction. The first adapter piece is connected to the second adapter piece by a conductive structure. In this application, the adapter component is designed to include a first adapter piece and a second adapter piece disposed discretely. Therefore, during assembling, the first adapter piece may be connected to the electrode post in advance, and then the second adapter piece is connected to the tab of the electrode assembly, and then the electrode assembly is put into the housing. Subsequently, the ends of the first adapter piece and the second adapter piece are connected by a conductive structure, so that the electrode assembly is loaded into the housing.