Bi-metal Battery Tab With Interlocking Pin And Socket
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rechargeable lithium batteries face challenges in efficiently coupling battery cell terminals to external elements while maintaining safety and minimizing material usage, especially as devices become smaller and more powerful, requiring more energy storage in a compact volume.
Innovation Solution
The development of a bi-metal tab configuration that includes an internal pin tab segment and an external socket tab segment, where the pin is enclosed within the socket, providing a secure and conductive connection with a protection layer to restrict electronic transport under specific physical conditions, enhancing safety and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional single-material tab is used to electrically couple battery cell terminals to external elements, then the manufacturing process is simple, but the mechanical strength and safety under adverse conditions are insufficient
Solution Approach 1:
The tab is constructed from two different metal materials: an internal tab segment made of a first metal material and an external tab segment made of a second metal material. This composite structure combines the advantages of different materials to achieve both mechanical strength and electrical conductivity while maintaining safety under adverse conditions.
Solution Approach 2:
The tab is divided into two distinct segments: an internal tab segment that couples to the battery cell terminal and an external tab segment that couples to external elements. This segmentation allows each segment to be optimized for its specific function, with the internal segment focusing on mechanical strength and the external segment on electrical conductivity.
2Reliability
If a protection layer is added to restrict electronic transport under adverse conditions, then safety is enhanced, but the device complexity increases
Solution Approach 1:
A protection layer is introduced as an intermediary component between the internal and external tab segments. This protection layer acts as a mediator that restricts electronic transport under adverse conditions, enhancing safety without requiring fundamental changes to the tab's basic structure.
3Volume of moving object
If the battery cell volume is reduced to accommodate smaller devices, then device size is minimized, but the ability to store energy efficiently is compromised
Solution Approach 1:
The invention optimizes the tab's physical and electrical parameters to maintain efficient energy storage and transfer in smaller battery cells. By carefully selecting the dimensions, materials, and configuration of the tab segments, the design achieves high energy density without compromising the tab's ability to conduct electricity effectively.
4Loss of substance
If material usage is minimized to reduce weight and cost, then resource efficiency is improved, but the mechanical strength and reliability of the tab connection are reduced
Solution Approach 1:
Different regions of the tab are assigned different material properties and thicknesses based on their specific functional requirements. The internal tab segment uses a material optimized for mechanical strength and adhesion to the battery terminal, while the external tab segment uses a material optimized for electrical conductivity and connection to external elements. This local optimization ensures reliable connections with minimal material usage.
Data Source
AI summary
A bi-metal tab includes an internal tab segment that can be coupled to a battery cell terminal within an interior of the cell and an external tab segment that can be coupled to an element external to the cell. One tab segment includes a pin tab segment that comprises a pin, and another tab segment includes a socket tab segment comprised of a separate metal material, that comprises a socket. The socket can be at least partially enclosed, on at least two opposing sides, by the structure of the socket tab segment, and the socket and pin of the separate segments can be configured to couple, to form the tab, where at least two surfaces of the pin are in flush contact with the socket tab segment structure. A protection layer that restricts electronic transport across the tab based on exposure to particular physical conditions can be included between the tab segments.