Battery Cell Terminal Clamping Mechanism

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Solution Overview

Problem

Existing battery cell technologies face challenges in achieving reliable and efficient electrical connections between electrodes and terminal assemblies, particularly when using dissimilar materials like copper and aluminum, often requiring welding which can be difficult and prone to mechanical damage.

Innovation Solution

A battery cell design featuring a housing with an electrode stack assembly and terminal assembly where strip elements are clamped using a resilient counter-element and groove-like recess configuration, eliminating the need for welding and providing a secure, conductive connection without mechanical damage risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to connect strip elements and terminal assemblies, then electrical connection reliability is improved, but manufacturing complexity and difficulty increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical clamping system consisting of a base part, counter-element, and groove-like recess. This mechanical connection achieves reliable electrical contact without the complexity of welding dissimilar materials like copper and aluminum, directly resolving the contradiction between connection reliability and manufacturing ease.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If dissimilar materials (copper and aluminum) are used for electrodes and strip elements, then electrical conductivity is improved, but connection reliability deteriorates due to welding difficulties

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmaterial compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the connection method parameter from welding to mechanical clamping, which enables the use of dissimilar materials (copper electrodes with aluminum strip elements or vice versa) without the metallurgical compatibility issues that plague welding. This allows optimal electrical conductivity through material selection while avoiding welding-related reliability problems.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If welding is used to join strip elements to terminals, then electrical connection is achieved, but risk of mechanical damage increases

Engineering Contradiction:

Improveconnection stabilityVSAvoidmechanical damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent substitutes the welding process with a purely mechanical clamping arrangement where the counter-element resiliently engages with the groove-like recess to secure the strip element between the base part and counter-element. This eliminates thermal and mechanical stresses associated with welding that could damage the strip elements or electrodes, while maintaining stable electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If additional welding connections are added to ensure good electrical connection, then connection quality is improved, but device complexity increases

Engineering Contradiction:

Improveelectrical connection qualityVSAvoidnumber of connections

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the electrical connection function and mechanical securing function into a single integrated clamping structure. The base part with groove-like recess and resilient counter-element simultaneously provide mechanical retention and electrical contact, eliminating the need for separate welding operations and reducing overall device complexity while maintaining connection quality.

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 ensures a robust and efficient electrical connection between electrodes and terminal assemblies, allowing for the use of copper without welding, enhancing reliability and compactness while protecting the connection from external damage.

Implementation Method 1

the counter-element resiliently engages with at least one groove-like recess of the base part in such a way that a first force is applied to the first contact face and the second contact face, pushing them towards one another

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20230261344A1Battery cell

Publication Date: 2023.08.17 DR ING H C F PORSCHE AG

AI summary

A battery cell includes a housing, an electrode stack assembly, and at least one terminal assembly. The electrode stack assembly is arranged in the housing and includes first electrode assemblies and second electrode assemblies. The first electrode assemblies include first electrodes and first strip elements. The second electrode assemblies include second electrodes and second strip elements. At least one terminal assembly includes a base part and a counter-element, which base part includes a first contact face and the counter-element includes a second contact face. The counter-element resiliently engages with at least one groove-like recess of the base part in such a way that a first force is applied to the first contact face and the second contact fact, pushing them towards one another. The first strip elements or second strip elements are arranged between the first contact face and the second contact face.