Variable-Length Battery Cell Frame for Weld-Free Lead Assembly
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Solution Overview
Problem
Conventional battery cell frames require manual labor for electrode lead bending and welding, leading to reduced weldability and increased error ratios due to size variability and thermal resin introduction, resulting in inefficient assembly and potential short circuits.
Innovation Solution
A battery cell frame with a variable length support member and bus bar system, including a spiral spring for length adjustment and thermal interface material integration, allowing for secure coupling of electrode leads and improved heat dissipation, reducing assembly errors and enhancing weldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are bent and welded manually to bus bar, then electrical connection is achieved, but weldability is reduced due to elastic resilience and overlap issues
Solution Approach 1:
A clamp member is introduced as an intermediary component between the electrode lead and bus bar. The clamp member secures the electrode lead to the bus bar through mechanical clamping, eliminating the need for welding while ensuring reliable electrical connection. This resolves the contradiction by providing a welding-free connection method that maintains both reliability and ease of manufacture.
2Adaptability or versatility
If frames in different sizes are used for various battery cell sizes, then each cell size is accommodated, but productivity is reduced due to multiple frame types
Solution Approach 1:
The frame structure incorporates movable and adjustable components that allow it to dynamically adapt to different battery cell sizes. Instead of using fixed-size frames, the frame can be reconfigured or adjusted to accommodate various cell dimensions, enabling a single frame design to serve multiple size requirements and thereby improving productivity.
Solution Approach 2:
The frame is designed with universal features that enable it to function with multiple battery cell sizes. Through standardized interfaces and adjustable mechanisms, a single frame design can accommodate different cell configurations, eliminating the need for multiple specialized frames and enhancing assembly efficiency.
3Temperature
If thermal resin is introduced after battery cell assembly, then thermal management is achieved, but error ratio increases due to post-assembly intervention
Solution Approach 1:
Thermal management features are integrated into the frame structure before battery cell assembly occurs. Thermal pathways, heat sinks, or thermally conductive materials are pre-positioned in the frame design, allowing thermal resin or thermal contact to be established during the assembly process itself rather than as a post-assembly step. This preliminary integration reduces manufacturing errors and improves precision.
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 efficient assembly of battery cells of various sizes with reduced error ratios and improved weldability, preventing overlap and enhancing heat dissipation efficiency.
Implementation Method 1
a variable length part formed in the support member and which changes in length to fit a size of the battery cell
Implementation Method 2
thermal interface material with which a battery cell comes into contact
Data Source
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AI summary
Disclosed is a battery cell frame. The battery cell frame according to an embodiment of the present disclosure includes a bus bar which is electrically coupled to an electrode lead of a battery cell, a support member which is coupled to the bus bar and with which the battery cell comes into contact to support the battery cell, and a variable length part formed in the support member and which changes in length to fit a size of the battery cell.