Battery Feedthrough Connector Assembly for Higher Energy Density
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Solution Overview
Problem
The conventional riveted structure of electrode posts in electrochemical devices is complex, costly, and occupies significant space, leading to reduced energy density in batteries.
Innovation Solution
An electrochemical device design featuring a housing with a cover, insulator, connecting strip, and feedthrough connector, which simplifies the manufacturing process, reduces parts, and increases the accommodation cavity space, using a connecting strip to secure the insulator and feedthrough connector, allowing for easier assembly and disassembly, and enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional riveted structure with multiple components (metal gasket, plastic gasket, electrode post) is used to fix the electrode post, then the structural strength and reliability are improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges the metal gasket, plastic gasket, and electrode post into an integrated feedthrough connector assembly. The feedthrough connector is directly integrated with the insulator, eliminating the need for separate metal and plastic gaskets. This consolidation maintains structural integrity while reducing component count and simplifying the assembly process.
Solution Approach 2:
The feedthrough connector serves multiple functions simultaneously: it provides electrical connection, mechanical support, and sealing. The insulator integrates the functions of electrical insulation, mechanical support, and sealing in a single component. This multi-functionality reduces the overall complexity of the electrode post structure.
2Stability of the object's composition
If a conventional riveted electrode post structure is used, then the structural stability is improved, but the space occupied in the housing increases, reducing energy density
Solution Approach 1:
The insulator and feedthrough connector are merged into an integrated assembly that reduces overall volume. The connecting strip is directly connected to the insulator without requiring additional gaskets or fasteners, minimizing the space required for the electrode post structure while maintaining structural stability.
Solution Approach 2:
The feedthrough connector is nested within the insulator structure, with the second part of the feedthrough connector extending through the insulator. This nested arrangement optimizes space utilization and reduces the overall volume occupied by the electrode post assembly.
3Strength
If a conventional riveted structure with multiple components is used, then the structural integrity is improved, but the manufacturing process becomes more complicated and costly
Solution Approach 1:
The feedthrough connector, insulator, and connecting strip are designed as an integrated assembly that can be manufactured as a single unit or pre-assembled module. This eliminates the need for multiple separate manufacturing processes and assembly steps, reducing manufacturing complexity and cost while maintaining structural integrity.
Solution Approach 2:
The insulator and feedthrough connector can be pre-assembled or pre-positioned before final installation into the housing. The connecting strip is pre-connected to the insulator, allowing for easier integration into the overall device assembly and reducing on-site manufacturing complexity.
4Reliability
If a conventional riveted electrode post structure is used, then the electrical connection reliability is improved, but the production cost increases due to multiple components and complex assembly
Solution Approach 1:
The electrical connection components (feedthrough connector, insulator, connecting strip) are merged into an integrated assembly that ensures reliable electrical connection while reducing the number of potential failure points. Fewer separate components mean fewer assembly steps and lower production costs, while the integrated design maintains electrical connection reliability.
Data Source
AI summary
An electrochemical device includes a housing, an insulator, a connecting strip and a feedthrough connector. The housing defines an accommodation cavity and includes a cover having a second surface. The cover includes a first through-hole. A second through-hole of the connecting strip communicates with the first through-hole. The insulator is fitly connected to the connecting strip. The insulator includes a third through-hole communicating with the second through-hole. A first part of the feedthrough connector is fitly connected to a surface of the insulator being away from the connecting strip. The first part covers the third through-hole. One end of a second part of the feedthrough connector is connected to a surface of the first part oriented toward the connecting strip. The second part extends away from the first part and is partly disposed in the first through-hole, the second through-hole, and the third through-hole.