Bent Contact Sheet Metal Member for Low-Dead-Volume Energy Storage
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Solution Overview
Problem
Existing contact sheet metal members in energy storage elements contribute to dead volume, reducing energy density due to their design, which necessitates minimizing space within the housing while maintaining effective electrical contact and structural integrity.
Innovation Solution
A contact sheet metal member with a first and second contacting section and a connecting section, featuring bending zones and a recess or aperture to minimize dead volume, allowing for compact assembly and efficient electrical connection within the energy storage element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional contact sheet metal member design is used, then electrical contact function is achieved, but dead volume increases reducing energy density
Solution Approach 1:
The contact sheet metal member is inserted into a recess of the lid, nesting one component within another. This eliminates dead volume by utilizing the recess space that would otherwise be empty, while maintaining the electrical contact function through the protruding contact section.
Solution Approach 2:
The contact sheet metal member features a three-dimensional structure with bending zones creating vertical and horizontal extensions. This multi-dimensional configuration allows the component to perform electrical contact while occupying minimal horizontal footprint, effectively utilizing vertical space to reduce dead volume.
2Volume of stationary object
If the contact sheet metal member is made compact, then dead volume is minimized, but manufacturing complexity increases
Solution Approach 1:
The contact sheet metal member is divided into distinct functional sections: a contact section for electrical connection, bending zones for spatial configuration, and a connection section for structural attachment. This segmentation allows each part to be optimized independently while simplifying the overall manufacturing process through modular design.
Solution Approach 2:
The design utilizes controlled geometric parameters including bending radii, section thicknesses, and recess dimensions that can be adjusted during manufacturing. These parameter variations allow the component to achieve the desired compact form factor while maintaining manufacturability through standard sheet metal forming processes.
3Ease of manufacture
If the contact sheet metal member structure is simplified, then manufacturing is easier, but electrical contact effectiveness may be reduced
Solution Approach 1:
The contact sheet metal member integrates multiple functions into a single component: electrical contact, structural connection, and space-efficient positioning. By merging these functions, the design achieves manufacturing simplicity through reduced part count while maintaining effective electrical contact through the integrated contact section.
Data Source
AI summary
A contact sheet metal member includes a first contacting section for contacting a first component of an energy storage element, a second contacting section configured for contacting a second component of the storage element, and a connecting section disposed between the first contacting section and the second contacting section. The first contacting section, the second contacting section, and the connecting section have a top side and a bottom side. The top side of the connecting section faces the bottom side of the first contacting section and the bottom side of the connecting section faces the top side of the second contacting section. The member further includes a first bending zone and a second bending zone. The second contacting section has a recess or an aperture that forms a receptable for the first bending zone.