Battery Contact Sheet With Bent Tabs for Precise Cell Assembly
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Solution Overview
Problem
The challenge lies in precisely placing a contact sheet metal part on the end face of an electrode-separator composite within electrochemical energy storage elements, particularly in cylindrical designs, where production-related fluctuations and the presence of a contact sheet metal part welded onto the composite can lead to increased internal resistance and insertion difficulties.
Innovation Solution
The solution involves a contact sheet metal part with bent extensions or protruding areas that are designed to enclose a specific bending angle, allowing for precise placement and centering on the electrode-separator composite, facilitating easier insertion into a housing by adapting to the composite's dimensions and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contact sheet metal part is welded onto the electrode-separator composite, then electrical connection is achieved, but placement precision deteriorates due to production-related fluctuations
Solution Approach 1:
The contact sheet metal part is pre-formed with bent extensions before assembly. These extensions are already shaped to match the expected geometry of the electrode-separator composite, allowing for automatic self-alignment during assembly and eliminating the need for high-precision placement operations.
Solution Approach 2:
The contact sheet metal part is designed with bendable extensions that can deform during assembly to adapt to variations in the electrode-separator composite dimensions. This flexibility compensates for production tolerances and maintains reliable electrical connection despite placement variations.
2Reliability
If a contact sheet metal part is welded onto the electrode-separator composite, then electrical connection is established, but internal resistance increases
Solution Approach 1:
The bent extensions are pre-formed to ensure optimal contact geometry with the electrode-separator composite. This preliminary shaping ensures that the contact area is maximized and contact pressure is optimally distributed, minimizing contact resistance and overall internal resistance of the energy storage element.
3Reliability
If a contact sheet metal part is placed on the end face, then electrical connection is achieved, but insertion into housing becomes difficult
Solution Approach 1:
The contact sheet metal part is pre-formed with bent extensions that will automatically engage with the electrode-separator composite during assembly. This preliminary configuration allows the contact part to be inserted into the housing along with the composite without requiring separate, complex assembly operations.
Solution Approach 2:
The contact sheet metal part and the electrode-separator composite are combined into a single assembly unit. The bent extensions of the contact part wrap around or engage with the composite, creating an integrated structure that simplifies handling and insertion into the housing as one piece.
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 approach enhances the precision of contact sheet metal part placement, reduces internal resistance, and simplifies the insertion process, thereby maximizing the energy density of the energy storage element by ensuring optimal contact and alignment with the electrode-separator composite.
Implementation Method 1
The contact sheet part is connected to the longitudinal edge by welding
Data Source
Figure 1
Figure 2~2B
Figure 3~3B
AI summary
An electrochemical energy storage element (100) with a housing is proposed. An electrode-separator assembly (104) is arranged within the housing. The electrode-separator assembly (104) comprises a side (104a, 104b) bounded by a circumferential rim or rims. A contact plate part (110) rests on the side (104a, 104b) of the electrode-separator assembly (104) and is welded to the electrode-separator assembly in the region of the side. The energy storage element (100) is further characterized in that the contact plate part (110) comprises at least one part (120) that is bent in the direction of the electrode-separator assembly (104), in particular bent over the rim or a rim bounding the side.