Battery Cell Lead Strength Testing Under Swelling Displacement
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Solution Overview
Problem
There is a lack of normalized testing apparatus and methods to assess the strength of the connection between the cell body portion and electrode lead in battery cells, which can lead to disconnection and safety issues due to swelling, particularly in battery modules for electric vehicles.
Innovation Solution
A battery cell strength testing jig and apparatus that generates relative displacement between the cell body portion and electrode lead, allowing for the measurement of load and limit load, simulating swelling to inform battery module design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a battery cell undergoes swelling during charging and discharging, then the battery cell can be repeatedly charged and discharged, but relative displacement occurs between the cell body portion and electrode lead causing disconnection and safety risks
Solution Approach 1:
The patent applies preliminary action by performing strength testing on the terrace portion before the battery cell is put into actual service. The testing apparatus pre-identifies weak connections between the electrode lead and cell body that could fail during swelling cycles, allowing manufacturers to screen out defective cells before assembly into battery modules, thus preventing future disconnections and safety incidents
Solution Approach 2:
The patent implements preliminary anti-action by applying controlled loads in the testing apparatus that simulate the stresses of swelling in reverse. The testing jig applies tensile and shear forces to the terrace portion to pre-stress and strengthen the connection, creating a more robust joint that can withstand the repeated swelling and shrinking cycles during actual battery operation
2Manufacturing precision
If standardized strength testing of the terrace portion is implemented, then battery module design can be improved, but currently no normalized testing apparatus exists
Solution Approach 1:
The patent applies segmentation by dividing the testing apparatus into separate, modular components: a testing jig with adjustable clamps for different cell sizes, a loading mechanism with standardized force application points, and a measurement system for displacement and force. This modular design allows the apparatus to be adapted to various battery cell types without requiring complete redesign, reducing overall device complexity while maintaining manufacturing precision
Solution Approach 2:
The patent implements universality by designing a testing apparatus that can evaluate multiple types of connections (terrace portions, welds, mechanical tabs) across different battery cell formats (cylindrical, prismatic, pouch). The standardized testing methodology and adjustable fixture system allow a single apparatus to serve multiple testing functions, eliminating the need for separate specialized equipment for each connection type or cell format
Data Source
AI summary
A battery cell strength testing jig includes a lead gripper in which an electrode lead drawn out from a side portion of a battery cell is fixed. The battery cell strength testing jig further includes a cell fixing member in which the battery cell is fixed. The cell fixing member is installed to be movable in a thickness direction of the battery cell. A relative displacement occurs between a cell body portion and the electrode lead of the battery cell when the cell fixing member is moved.