Battery Connection Member Bending for Higher Cell Space Utilization
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Solution Overview
Problem
Lithium-ion batteries face challenges in space utilization and energy density due to the need for a large welding area to prevent temperature rise from overcurrent, leading to low space utilization and potential damage during bending of connection members.
Innovation Solution
A connection member with a guide plate and a first connecting plate, featuring indentations that facilitate accurate bending, reducing the risk of damage and improving assembly by forming a thin part between the plates, thereby enhancing space utilization and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first connecting plate is made larger to provide sufficient welding area, then the protection against temperature rise from overcurrent is improved, but the space utilization and energy density of the battery core deteriorate
Solution Approach 1:
The first connecting plate is bent along a bending line to change its spatial orientation from a planar configuration to a three-dimensional folded structure. This dimensional transformation allows the connecting plate to maintain sufficient welding area while reducing its projection area on the battery core, thereby improving space utilization and energy density without compromising overcurrent protection capability
2Volume of moving object
If the first connecting plate is bent to improve space utilization, then the space utilization and energy density are improved, but the connection member may be damaged during bending
Solution Approach 1:
A relief groove is introduced at the bending line of the first connecting plate, creating a localized region with reduced material thickness. This local quality change concentrates the bending deformation in the relief groove area, protecting the rest of the connecting plate from damage while enabling successful bending to achieve improved space utilization
3Manufacturing precision
If the bending position is not accurate, then the assembly of battery core and housing is affected, but providing precise bending control increases manufacturing complexity
Solution Approach 1:
The relief groove is pre-formed at the exact bending line position before the bending operation. This preliminary action establishes a predetermined bending path that guides the deformation process, ensuring accurate bending position and proper assembly without requiring complex real-time control systems during manufacturing
Data Source
AI summary
A rechargeable battery includes a battery core, a connection member, and a gasket. The connection member includes a guide plate and a first connecting plate integrally formed on the guide plate and connected to a tab of the battery core. The first connecting plate is disposed in a bendable manner relative to the guide plate, and at least one indentation is present between the first connecting plate and the guide plate. The gasket is fastened to the first connecting plate and the tab. The tab is sandwiched between the first connecting plate and the gasket.