Battery Connection Member Bending for Higher Cell Energy Density
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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 the bending process 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, thus enhancing space utilization and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first connecting plate is made large enough in longitudinal direction to provide sufficient welding area, then temperature rise from overcurrent is protected against, but space utilization and energy density become low
Solution Approach 1:
The first connecting plate is bent along a bending line from an initial state (extending in longitudinal direction) to a final state (extending in width direction), changing the spatial dimension of the component. This dimensional transformation allows the same welding area to be achieved with reduced longitudinal occupation, thereby improving space utilization and energy density while maintaining reliability
2Volume of moving object
If the first connecting plate is bent to improve space utilization, then energy density increases, but the bending position accuracy becomes difficult to control
Solution Approach 1:
A guide plate is introduced as an intermediary component during the bending process. The guide plate provides a predetermined bending line that guides the first connecting plate during bending, ensuring accurate bending position. After bending, the guide plate is removed, having served its purpose as a temporary positioning aid
3Volume of moving object
If the first connecting plate is bent to reduce spatial size, then energy density improves, but damage to the connection member during bending increases
Solution Approach 1:
The guide plate acts as a mediator that distributes and guides the bending force along a predetermined path. This prevents concentrated stress and potential damage to the first connecting plate by ensuring the bending occurs at the correct location and in the correct manner
Solution Approach 2:
The guide plate is positioned in advance to establish the bending line before the actual bending process begins. This preliminary positioning ensures that when bending force is applied, it acts along the predetermined path, reducing the risk of misalignment and damage
Data Source
AI summary
A connection member includes a guide plate and a first connecting plate integrally formed on the guide plate. 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. A portion, of the guide plate except a part corresponding to the at least one indentation, connected to the first connecting plate becomes gradually thinner in a direction from the guide plate to the first connecting plate.