Battery Feedthrough Head Part Design for Hermetic Sealing
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Solution Overview
Problem
Lithium-ion batteries in automotive applications face challenges such as corrosion resistance, vibration resistance, and hermetic tightness issues due to the limitations of current feedthroughs and electrode connections, which can lead to reduced service life and heat loss problems.
Innovation Solution
A feedthrough component with a pin-shaped conductor and a head part made of glass or glass ceramic material, where the head part is larger than the conductor, providing a mechanically stable and non-detachable electrical connection to the electrode connecting components, and is designed to minimize heat loss and installation space, using materials like aluminum or copper alloys for the conductor and electrode components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic insulation is used for electrodes, then ease of manufacture is improved, but reliability deteriorates due to limited temperature resistance, mechanical resistance, aging, and uncertain tightness
Solution Approach 1:
The patent replaces durable but complex glass or ceramic feedthroughs with simpler, more replaceable plastic insulators that can be easily manufactured and installed, accepting that they have limited service life but can be replaced without complex procedures
Solution Approach 2:
The patent modifies the properties of plastic materials through compound formulations and processing parameters to enhance their temperature resistance and mechanical strength, making them suitable for battery applications despite inherent material limitations
2Reliability
If glass or ceramic feedthroughs are used, then reliability is improved through hermetic sealing, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent extracts the insulating function from complex glass-ceramic feedthrough assemblies and implements it through simpler plastic insulator components combined with metal connectors, separating the hermetic sealing function from the electrical connection function
Solution Approach 2:
The patent divides the feedthrough assembly into separate functional components: plastic insulators for electrical isolation, metal connectors for electrical connection, and gaskets for hermetic sealing, allowing each component to be optimized independently
3Strength
If crimped and laser-welded connecting components are used, then mechanical strength is improved, but heat loss increases due to resistance losses from additional insulators in the interior
Solution Approach 1:
The patent removes additional insulators from the interior of the battery assembly, extracting only the essential insulating function to minimal necessary components, thereby reducing resistance losses and heat generation from multiple interface connections
Solution Approach 2:
The patent combines the insulating and connecting functions into integrated plastic insulator assemblies with built-in metal connectors, eliminating separate insulator components and reducing the number of connection interfaces that generate heat
4Ease of operation
If battery cells have large installation space, then ease of operation is improved, but use of energy deteriorates due to heating from high currents and resistance losses
Solution Approach 1:
The patent changes the electrical resistance parameter by optimizing conductor materials, cross-sectional areas, and connection geometries to minimize I²R losses, allowing efficient current conduction in compact battery cell designs
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
The solution enhances the stability and durability of the battery connections, reduces heat loss, and allows for optimized material selection and production of separate components, resulting in improved resistance to mechanical stress and thermal expansion, while maintaining hermetic sealing and reducing the risk of short circuits.
Implementation Method 1
The feedthrough is a glass or glass ceramic material with a substantially pin-shaped conductor and a head part... ensuring hermetic tightness over a long period of time
Implementation Method 2
The head part is designed in such a way that it can be connected to an electrode connecting part... by welding, in particular laser welding, resistance welding, electron beam welding
Implementation Method 3
laser welding, resistance welding, electron beam welding
Implementation Method 4
laser welding, resistance welding, electron beam welding
Implementation Method 5
laser welding, resistance welding, electron beam welding
Implementation Method 6
friction welding, ultrasonic welding
Implementation Method 7
friction welding, ultrasonic welding
Data Source
Figure 1~2
Figure 3a~4b
Figure 5a~5b
AI summary
The invention relates to a feed-through component for a conductor feed-through which passes through a housing part of a housing, in particular a battery housing, which is embedded in a glass or glass ceramic material and has at least one conductor, in particular an essentially pin-shaped conductor and a head part. The invention is characterised in that the surface, in particular the cross-sectional surface of the head part is greater than the surface, in particular the cross-sectional surface of the conductor, in particular of the essentially pin-shaped conductor and the head part is embodied such that is can be joined to an electrode-connecting component, in particular electrode-connecting part, in particular made of copper, a copper alloy CuSiC, an aluminium alloy AlSiC or aluminium, by means of a mechanically stable and non-detachable connection.