Cap Assembly Horizontal Tab Welding Low Impedance
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Solution Overview
Problem
Conventional energy delivery devices face challenges with high electrical impedance and space inefficiency due to mechanical connections and long tab lengths, which hinder effective current transmission in battery cells.
Innovation Solution
A cap assembly featuring horizontally oriented current collecting tabs welded to a tab collection post and core insert, reducing impedance through direct electrical connections and minimizing vertical space requirements, with optional rivets and shock absorbers for enhanced assembly and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical connections (threaded connections, nuts) are used to connect tabs to terminals, then assembly is easier and components are secure, but electrical impedance increases
Solution Approach 1:
The patent replaces mechanical connections (threaded connections, nuts, bolts) with direct welding connections between tabs and terminals. This substitution eliminates the high impedance associated with mechanical interfaces while maintaining secure electrical connection through metallurgical bonding.
Solution Approach 2:
The patent merges the tab and terminal into a single integrated component structure where the tab is directly welded to the terminal, eliminating the need for separate fastening components. This merging reduces the number of interfaces and associated impedance.
2Object-generated harmful factors
If vertical tab connection orientation is used, then current transmission path is direct, but considerable vertical space is required in the cell
Solution Approach 1:
The patent transitions from a vertical tab connection orientation to a horizontal orientation, changing the spatial dimension in which the current transmission path is established. This dimensional change allows the current to flow horizontally through the cell structure, reducing the vertical space requirement while maintaining direct current transmission.
3Reliability
If long tab lengths are used to reach from electrode connection points to terminal, then connectivity is achieved, but impedance increases and space is wasted
Solution Approach 1:
The patent extracts and eliminates the excessive tab length that extends beyond what is necessary for direct connection. By removing the redundant portion of the tab, the design achieves direct electrical connectivity with minimal tab length, thereby reducing impedance and optimizing space utilization.
4Adaptability or versatility
If multiple components are used in the current path, then assembly flexibility is improved, but impedance increases due to multiple connection points
Solution Approach 1:
The patent merges multiple separate components (tabs, terminals, fasteners) into a simplified integrated structure where the tab is directly welded to the terminal. This merging reduces the number of connection points in the current path, thereby reducing cumulative impedance while maintaining assembly flexibility through the welding process.
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 cap assembly achieves low impedance and space-efficient current transmission by eliminating mechanical connections and reducing tab lengths, thereby improving the efficiency and compactness of battery cells.
Implementation Method 1
electric current is carried from a battery electrode foil to a centrally located terminal
Implementation Method 2
The current collecting tab is disposed in a welded engagement with the tab collection post and the core insert
Data Source
AI summary
A cap assembly for use in an electrochemical cell. The cap assembly includes a tab collection post, a core insert, and at least one current collecting tab connected at one end to an electrode foil in the electrochemical cell, and horizontally connected at the other end to the tab collection post and the core insert. The at least one current collecting tab is disposed between and welded with the tab collection post and the core insert. The cap assembly also includes a shock absorber disposed around the core insert.