Bent Contact Sheet Metal for Battery Cell Insertion Alignment

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Solution Overview

Problem

The insertion of an electrode-separator assembly into a housing can be challenging due to the risk of damage or failure, especially when a contact sheet metal member is welded onto the assembly, requiring precise positioning which can be difficult in industrial manufacturing processes.

Innovation Solution

The electrochemical energy storage element incorporates a contact sheet metal member that is bent in a direction towards the electrode-separator assembly, facilitating precise placement and centering on the end face of the assembly, thereby simplifying the insertion process into a housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a contact sheet metal member is welded onto the electrode-separator assembly, then electrical connection is improved, but positioning precision becomes difficult to achieve

Engineering Contradiction:

Improveelectrical connectionVSAvoidpositioning precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The contact sheet metal member is pre-bent before welding to achieve the desired positioning. The bending is performed in advance as a preliminary action, allowing the component to be self-aligning during the welding process, thus achieving both reliable electrical connection and positioning precision without requiring complex positioning fixtures during welding.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The geometric parameters of the contact sheet metal member are changed by bending it into a specific shape. This parameter change (from flat to bent) enables the component to conform to the electrode-separator assembly surface and achieve accurate positioning while maintaining good electrical contact through the bent configuration.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If the contact sheet metal member is made rigid for stable welding, then welding stability is improved, but ease of positioning deteriorates

Engineering Contradiction:

Improvewelding stabilityVSAvoidease of positioning

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The contact sheet metal member is pre-bent to the required position before the welding operation. This preliminary positioning action allows the rigid component to be placed in the correct position beforehand, after which the rigid structure provides stability during welding without requiring flexibility during the welding process itself.

Inventive Principle:

Principle #10Preliminary action

3Quantity of substance

If the electrode-separator assembly dimensions are maximized for higher energy density, then energy density is improved, but risk of damage during insertion increases

Engineering Contradiction:

Improveenergy densityVSAvoidinsertion reliability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The contact sheet metal member is pre-bent to facilitate smooth insertion of the electrode-separator assembly into the housing. This preliminary shaping of the contact member creates a guiding effect that directs the assembly during insertion, reducing the risk of damage even when the assembly dimensions are maximized for higher energy density.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The bent contact sheet metal member acts as a cushioning element during insertion. The bent configuration absorbs insertion forces and provides a gradual transition during the insertion process, protecting the maximized electrode-separator assembly from damage while allowing larger dimensions for higher energy density.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

The bent contact sheet metal member ensures accurate positioning and alignment, reducing the risk of damage during insertion and allowing for maximization of the assembly's dimensions within the housing, thereby enhancing the energy density of the energy storage element.

Implementation Method 1

The contact sheet metal member comprises at least one part which is bent in a direction of the electrode-separator assembly

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

which is connected to the electrode-separator assembly in a region of the side by welding

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20250030007A1Electrochemical energy storage element with a contact sheet metal member and method of manufacturing the same

Publication Date: 2025.01.23 VARTA MICROBATTERY GMBH

AI summary

An electrochemical energy storage element includes a housing and an electrode-separator assembly arranged inside the housing. The electrode-separator assembly includes a side that is delimited by a circumferential edge or multiple edges. The electrochemical energy storage element further includes a contact sheet metal member that rests on the side of the electrode-separator assembly and that is connected to the electrode-separator assembly in a region of the side by welding. The contact sheet metal member comprises at least one part that is bent in a direction of the electrode-separator assembly.