Battery Cell Tab-Pin Groove Structure for Higher Energy Density

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Solution Overview

Problem

The existing connection method between tabs and pins in battery cells results in inefficient use of space, leading to low energy density due to overlapping tabs and the generation of metal shavings during the cutting process, which can cause insulation failures.

Innovation Solution

A battery cell structure where tabs protrude from the battery cell body and are attached to a tab guide part with a groove, allowing part of the tab to be hidden in the thickness space, eliminating the need for cutting and reducing space occupation, thus improving energy density and ensuring insulation integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If tabs are wrapped on pins from both sides, then electrical connection is achieved, but tab overlapping increases thickness and reduces energy density

Engineering Contradiction:

Improveelectrical connectionVSAvoidspace occupation

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The tab is nested within the groove of the pin structure. The groove is formed by concaving a part of the outer surface of the pin, and the tab is partially accommodated in this groove, allowing the tab to be hidden in the thickness space of the pin rather than overlapping externally.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The tab is bent from one side of the pin to the outer surface, changing its spatial arrangement from a flat overlapping configuration to a three-dimensional configuration that utilizes the groove depth direction, thereby reducing the thickness occupation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If tabs are cut to reduce thickness, then space is saved, but metal shavings are generated causing insulation failure

Engineering Contradiction:

Improvespace occupationVSAvoidinsulation

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The groove is pre-formed on the pin outer surface before tab installation. This preliminary preparation allows the tab to be accommodated without requiring subsequent cutting operations, thus preventing metal shaving generation while achieving space reduction.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If tabs overlap pins, then connection is achieved, but internal battery space is reduced

Engineering Contradiction:

ImproveconnectionVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS20240222805A1Battery cell structure, battery module and battery pack

Publication Date: 2024.07.04 AESC JAPAN LTD

AI summary

Disclosed are a battery cell structure, a battery module and a battery pack. The battery cell structure includes a housing, an electrode assembly, a top cover assembly and a pin part. The electrode assembly is arranged in the housing. The electrode assembly includes a battery cell body and a tab extending from the battery cell body, the top cover assembly includes a top cover body and electrode terminals arranged thereon. The top cover body is connected to the housing, the pin part includes a terminal connection part and a tab guide part connected to each other, and the terminal connection part is connected to the electrode terminal. The tab guide part is connected to the tab, the terminal connection part is connected to the tab guide part, and one side of the tab guide part away from the electrode assembly is the outer surface.