Laminated Battery Tab-Pin Sliding Connection for Expansion
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Solution Overview
Problem
Laminated batteries face challenges during assembly due to the difficulty in placing the laminated core into the case without damaging the tabs, and during use, the tabs are prone to tearing due to expansion and displacement of the electrodes, leading to reduced production yield and performance.
Innovation Solution
The laminated battery design includes a laminated core with electrode clusters and pins, where the tabs form bundles connected to pins that are slidably connected to a connection portion within the cap assembly, allowing for electrical connection and reducing the risk of tab tearing during expansion by sliding on a slide rail, and the use of liquid reservoirs to manage electrolyte distribution and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the laminated core is placed into the case during assembly, then the battery structure is formed, but the tabs are prone to be folded or scratched
Solution Approach 1:
A protective cover is introduced as an intermediary component between the tabs and the case during assembly. The protective cover shields the tabs from direct contact with the case walls, preventing folding and scratching while allowing the laminated core to be properly positioned inside the case.
Solution Approach 2:
The protective cover is designed to be in place before the tabs contact the case during assembly, providing preemptive protection. This beforehand cushioning prevents damage before it can occur, ensuring tab integrity throughout the assembly process.
2Adaptability or versatility
If the laminated core expands during use, then the electrodes change position, but the tabs are prone to be torn due to fixed junction positions
Solution Approach 1:
The connection between the tabs and the cap assembly is changed from a fixed rigid connection to a dynamic movable connection. The cap assembly is designed to move or expand along with the laminated core, allowing the tab connection points to shift position dynamically. This maintains the relative position between tabs and connection points, preventing tab tearing during electrode expansion.
Solution Approach 2:
The physical parameters of the cap assembly (such as its dimensions or position) are allowed to change in response to electrode expansion. The cap assembly can expand, contract, or shift position to match the changing state of the laminated core, thereby maintaining proper alignment with the tabs and preventing mechanical failure.
3Reliability
If the tabs are welded to the cap assembly with fixed positions, then electrical connection is achieved, but the tabs cannot accommodate electrode displacement
Solution Approach 1:
The cap assembly incorporates movable connection structures that allow the electrical connection points to shift position dynamically. This could include sliding contacts, flexible connectors, or movable conductive elements that maintain electrical connectivity while accommodating the displacement caused by electrode expansion and contraction during battery operation.
Data Source
AI summary
A laminated core includes a case, a laminated core, and a cap assembly. The laminated core includes multiple electrode clusters. Each electrode cluster includes multiple laminated electrodes and multiple tabs. Each tab extends out of a corresponding one of the electrodes. The multiple tabs of each electrode clusters form a tab bundle, and the tab bundle is connected to one pin. The cap assembly includes a connection portion and a pole, the pin is slidably connected to the connection portion, and electrically connected to the pole through the connection portion.