Battery Cell Tab Deflection Structure for Fast-Charging Assembly

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Solution Overview

Problem

The complex and costly manufacturing process of battery cells for vehicles, particularly in achieving high energy density, is hindered by the need for multiple manufacturing steps and equipment investments, and the challenge of fast charging electric vehicles is exacerbated by electrical resistance losses during recharging.

Innovation Solution

Incorporating a deflection structure within the battery cell housing to deflect electrode tabs away from the wall, reducing the need for pre-assembly deflection and integrating process steps, combined with a thermally and electrically conductive bridging material to enhance electrical conductivity and reduce internal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If electrode tabs are deflected away from the wall during assembly, then electrical resistance losses are reduced and charging efficiency is improved, but manufacturing complexity and time increase due to additional pre-assembly steps

Engineering Contradiction:

Improveelectrical resistance lossesVSAvoidmanufacturing process complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The deflection structure is pre-integrated into the housing during housing manufacturing, so that the electrode tabs are automatically deflected away from the wall when inserted into the housing. This preliminary preparation of the housing eliminates the need for separate post-assembly deflection steps, reducing manufacturing complexity while maintaining the energy loss reduction benefit

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The deflection structure acts as an intermediary element between the housing wall and the electrode tabs. It provides a mechanical interface that automatically deflects the tabs away from the wall through its geometric design, solving the electrical resistance problem without requiring complex external deflection mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If multiple manufacturing steps and equipment are used to achieve high energy density, then battery cell performance is improved, but manufacturing cost and process complexity increase

Engineering Contradiction:

Improvebattery cell performanceVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The deflection structure is merged with the housing as an integrated component, combining two previously separate manufacturing processes (housing manufacturing and tab deflection) into one. This reduces the number of manufacturing steps and equipment requirements while maintaining the performance benefits of properly deflected tabs

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing serves multiple functions: it contains the electrode assembly, provides structural support, and through its integrated deflection structure, automatically positions the electrode tabs to reduce electrical resistance. This multi-functionality eliminates the need for separate deflection equipment, simplifying manufacturing while improving performance

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Speed

If fast charging is implemented to reduce recharging time, then vehicle operational efficiency is improved, but electrical resistance heat losses and cooling requirements increase

Engineering Contradiction:

Improvecharging speedVSAvoidelectrical resistance heat losses

Core Design Contradiction:

SpeedVSLoss of energy

Solution Approach 1:

The deflection structure is pre-configured in the housing to automatically position electrode tabs away from the wall during assembly. This preliminary geometric configuration reduces electrical resistance at the source, allowing fast charging to proceed with minimized heat generation, thereby reducing cooling requirements

Inventive Principle:

Principle #10Preliminary action

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 simplifies the manufacturing process, reduces costs, and improves charging efficiency by minimizing electrical resistance and heat losses, enabling faster charging and potentially downsizing cooling systems, thereby lowering vehicle costs and weight.

Implementation Method 1

a deflection structure configured to deflect at least some of the electrode tabs away from the wall

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

combined with a thermally and electrically conductive bridging material to enhance electrical conductivity and reduce internal resistance

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

combined with a thermally and electrically conductive bridging material to enhance electrical conductivity and reduce internal resistance

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250007133A1Battery cell, vehicle and method for manufacturing a battery cell

Publication Date: 2025.01.02 VOLVO CAR CORP

AI summary

A battery cell can comprise a housing comprising a wall, at least one battery terminal, and an electrode material comprising electrode tabs. At least a portion of the electrode material can extend along the wall inside the housing. The electrode tabs can be electrically connected to the at least one battery terminal. The battery cell can further comprise a deflection structure configured to deflect at least some of the electrode tabs away from the wall.