Battery Cell Tab Deflection Structure for Fast-Charging Conductivity
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Solution Overview
Problem
The complex and costly manufacturing process of battery cells for electric vehicles, particularly in achieving high energy density and efficient charging, is hindered by the need for multiple manufacturing steps and energy losses during recharging due to electrical resistance in wires.
Innovation Solution
A battery cell design featuring a deflection structure within the housing to bend electrode tabs away from the wall, eliminating the need for pre-deflection and incorporating a bridging material for improved electrical conductivity and heat removal, which simplifies manufacturing and enhances charging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode tabs are pre-deflected before insertion into housing, then electrical conductivity and charging efficiency are improved, but manufacturing complexity and time increase
Solution Approach 1:
The battery cell housing is designed with an integrated deflection structure that automatically deflects electrode tabs during the insertion process itself. The housing structure includes deflecting surfaces or features that contact and bend the tabs as they are inserted, eliminating the need for separate pre-deflection equipment or manual operations. This self-service approach maintains the electrical conductivity benefits while significantly simplifying the manufacturing process.
Solution Approach 2:
The deflection function is merged with the housing structure itself. Rather than being a separate component or process step, the deflection capability is integrated into the housing design through features such as deflecting surfaces, guide structures, or built-in mechanisms that perform the tab deflection during normal insertion operations. This merging reduces the number of manufacturing steps and equipment requirements.
2Reliability
If multiple manufacturing steps are used to achieve high energy density, then battery performance is improved, but production time and costs increase
Solution Approach 1:
The housing is pre-designed and pre-configured with deflection structures during housing manufacturing, so that when electrode tabs are inserted, the deflection action occurs automatically as part of the insertion process itself. This preliminary preparation of the housing structure eliminates the need for separate deflection steps during battery assembly, reducing manufacturing time while maintaining the electrical performance benefits of deflected tabs.
Solution Approach 2:
Multiple functions (housing containment, structural support, and tab deflection) are merged into a single integrated housing component. This consolidation reduces the total number of manufacturing steps and equipment requirements, thereby increasing production throughput while still achieving the high energy density targets through proper tab positioning and electrical contact.
3Speed
If high current is used for fast charging, then charging speed is improved, but electrical resistance losses and heat generation increase
Solution Approach 1:
The deflection structure modifies the physical parameters of the electrical connection by changing the contact area, contact pressure, and geometric alignment between electrode tabs and collection current structures. These parameter changes reduce electrical resistance at the connection interfaces, allowing higher charging currents to be transmitted with reduced energy losses and heat generation, thereby enabling faster charging.
4Reliability
If manual or separate-machine tab deflection is performed, then electrical contact is improved, but manufacturing cost and time increase
Solution Approach 1:
The housing structure performs the tab deflection function automatically during the insertion process. The deflecting surfaces or features built into the housing contact and bend the tabs as they are inserted, eliminating the need for separate deflection machines or manual operations. This self-service mechanism maintains high electrical contact quality while significantly simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The housing structure acts as an intermediary element that facilitates the tab deflection process. Rather than requiring direct manual manipulation or separate deflection equipment, the housing's built-in deflecting features serve as a mediator that automatically performs the necessary tab bending during normal insertion operations, improving ease of manufacture while maintaining contact quality.
Data Source
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AI summary
The disclosure relates to a battery cell (10) comprising a housing (20) having a wall (22) and at least one battery terminal (30, 40), the battery cell (10) comprising an electrode material (50) having electrode tabs (51), at least a portion of the electrode material (50) extending along the wall (22) inside the housing (20), the electrode tabs (51) being electrically connected to the at least one battery terminal (30, 40), and the battery cell (10) further comprising a deflection structure (80) configured to deflect at least some of the electrode tabs (51) away from the wall (22). The disclosure further relates to a vehicle comprising a battery unit, the battery unit having at least one of such battery cells (10). The disclosure further relates to a method (100) for manufacturing a battery cell (10).