Battery Cell Electrode Clamp Terminal for Higher Energy Density
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Solution Overview
Problem
The existing electrochemical cells for batteries, particularly in electric or hybrid vehicles, face challenges in achieving high energy density due to unnecessary volume created during assembly, which complicates handling and welding of electrode bundles, leading to reduced energy storage capacity within a given housing dimension.
Innovation Solution
The electrochemical cell design features a contact member with jaws that trap the distal portion of electrode bundles, allowing for parallel alignment and simplifying assembly by eliminating unnecessary welds, thereby reducing the space between the stack and housing and enhancing energy density without increasing assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a certain space is provided between the stack and the housing/cover to allow for assembly of electrode bundles, then the assembly process becomes feasible, but the energy density decreases due to unnecessary volume
Solution Approach 1:
The contact member is pre-formed with a cavity that is specifically shaped and sized to receive the electrode bundle in its final position. This preliminary preparation of the receiving structure eliminates the need for excessive clearance space during assembly, as the bundle is guided into its precise final position within the cavity.
Solution Approach 2:
The contact member acts as an intermediary structure between the electrode bundle and the housing/cover. Its cavity provides a controlled interface that accommodates the bundle during assembly while maintaining minimal overall spacing, thus resolving the conflict between assembly feasibility and space utilization.
2Ease of manufacture
If the electrode bundle is handled in a conventional manner, then the assembly process becomes complex requiring multiple welds, but the manufacturing time and complexity increase
Solution Approach 1:
The contact member integrates multiple functions: it provides electrical connection, mechanical support, and positional guidance for the electrode bundle. By combining these functions into a single component with a specifically shaped cavity, the design eliminates the need for separate alignment fixtures and multiple welding operations, thereby reducing manufacturing time and complexity.
Solution Approach 2:
The cavity in the contact member is designed to automatically guide and position the electrode bundle during assembly. The bundle self-aligns within the cavity without requiring complex external positioning mechanisms, and the design enables welding from only one side, making the assembly process self-sufficient and simpler.
3Manufacturing precision
If the distal portion of the electrode bundle is not constrained, then the bundle is difficult to position precisely, but the manufacturing precision decreases
Solution Approach 1:
The contact member features a cavity with specific local geometries including recesses and surfaces designed to interact with particular portions of the electrode bundle. The distal portion of the cavity provides localized constraint features that precisely position the bundle without requiring complex overall mechanisms, achieving high positioning precision through targeted local design.
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 increases energy density by 2% to 5% and simplifies the assembly process by reducing the distance between the stack and housing, while maintaining or reducing assembly complexity, and allows for more precise positioning of electrodes.
Implementation Method 1
the distal portion of the bundle being wedged between two jaws of the first contact member
Implementation Method 2
the sheets are welded together in the middle portion and/or in the distal portion
Data Source
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AI summary
Electrochemical cell (10) for battery, comprising: - a housing (12), and a cover, - a stack (16) of electrochemical elements (18), - a plurality of electrodes (20) comprising internal parts (22) forming some of the electrochemical elements, and sheets (24) emerging from a lateral face (26) of the stack and forming a bundle (52) having a proximal portion (54), a middle portion (56) and a distal portion (58), the sheets converging in the proximal portion towards the middle portion, and extending against each other in the distal portion, - an electrically conductive contact member (36) for electrically connecting the plurality of electrodes to an electrical terminal, the distal portion being clamped between two jaws (60, 62) of the contact member, and extending parallel to the lateral face.