Sliding Current Collector Battery Cell for Weld-Free Connections

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Solution Overview

Problem

Existing battery cell manufacturing processes are resource-intensive and complex, requiring labor-intensive methods like welding and hemming to ensure electrical connections, which increase costs and complexity.

Innovation Solution

A battery cell design featuring a second current collector with a variable height that slides along the housing, allowing it to adapt to thermal and mechanical loads, eliminating the need for welding or hemming by using a compressive force to maintain electrical contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to ensure electrical connections in battery cell manufacturing, then connection reliability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a purely mechanical compression system. The compressible element applies continuous compressive force to maintain electrical contact between current collectors and terminals, eliminating the need for welding operations while ensuring reliable electrical connections throughout the battery cell lifecycle.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The compressible element automatically adjusts and maintains electrical connections through its inherent compression capability. As the battery cell undergoes thermal expansion, contraction, or mechanical deformation during operation, the compressible element continuously adapts to maintain optimal contact pressure, providing self-regulating connection reliability without external intervention or complex control systems.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If welding processes are used in battery cell assembly, then electrical connection quality is improved, but manufacturing time and resource consumption increase

Engineering Contradiction:

Improveelectrical connection qualityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention substitutes complex welding processes with a simple mechanical compression mechanism. The compressible element maintains electrical connections through continuous compressive force, eliminating time-consuming welding operations, quality control checks, and maintenance activities while ensuring consistent connection quality throughout production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent separates the connection maintenance function from the assembly process. Instead of requiring precise welding operations during assembly, the compressible element is designed to automatically maintain connections throughout the battery cell lifecycle, decoupling connection quality from manufacturing precision requirements and enabling faster, simpler assembly processes.

Inventive Principle:

Principle #1Segmentation

3Reliability

If conventional battery cell designs are used, then manufacturing process is established, but adaptability to thermal and mechanical loads is insufficient

Engineering Contradiction:

Improvedurability under thermal and mechanical loadsVSAvoidadaptability to environmental conditions

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent introduces dynamic adaptability through the compressible element, which continuously adjusts its compression force in response to thermal expansion, contraction, and mechanical deformation of the battery cell. This dynamic behavior enables the system to adapt to varying environmental conditions and operational stresses, maintaining reliable electrical connections throughout the battery cell lifecycle under diverse thermal and mechanical loads.

Inventive Principle:

Principle #15Dynamics

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, reduces manufacturing costs, and enhances durability and performance by dynamically adapting to environmental conditions, improving the battery cell's lifetime and efficiency.

Implementation Method 1

the second current collector being configured with a variable height along an extension axis of the housing, the variable height varying based on a thermal load of the electrode assembly

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250349991A1Battery cell for a vehicle

Publication Date: 2025.11.13 VOLVO CAR CORP

AI summary

The disclosure relates to a battery cell comprising a housing having an inner wall, a first battery terminal and a second battery terminal, the battery cell further comprising an electrode assembly with a first electrode having a first current collector electrically connected to the first battery terminal and a second electrode having a second current collector electrically connected to the second battery terminal, the second current collector is configured with a variable height along an extension axis of the housing, the variable height varying based on a temperature of the electrode assembly, and the second current collector is able to slide along the extension axis the relative to the housing.