Cell Connector with Offset Tabs for Battery Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In high packing density applications like vehicle batteries, connecting individual galvanic cells is challenging due to large connecting surfaces and limited space for tools, especially with flexible pouch cells where terminal tabs are difficult to access for welding, limiting the use of bulky tools and increasing the number of welding steps required for thick cells.
Innovation Solution
A cell connector system with offset connecting tabs arranged at right angles to enhance accessibility, allowing for the use of solid tools and enabling efficient ultrasonic welding of galvanic cells, including thin pouch cells, by providing a U-shaped or extruded U-profile design with overlapping or free space regions for improved access and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pouch cells are connected using traditional welding methods, then electrical connection is achieved, but tool accessibility is limited and the number of welding steps increases
Solution Approach 1:
The patent introduces a third dimension by folding the connecting tabs at right angles to the cell stack surface, allowing welding tools to access terminal tabs from a lateral direction rather than only from the top or bottom, thereby improving tool accessibility without increasing the number of welding steps
Solution Approach 2:
The connecting tabs are segmented into multiple sections with different orientations (first connecting tabs perpendicular to cell length, second connecting tabs perpendicular to cell width), allowing different portions of the connection to be made at different stages and from different access directions
2Productivity
If thick pouch cells (>7mm) are welded using ultrasonic welding, then joining is achieved, but the joining area is limited to 25mm² per working step requiring multiple welding steps
Solution Approach 1:
By folding connecting tabs at right angles, the patent enables ultrasonic welding tools to access terminal tabs from lateral positions, allowing larger joining areas to be achieved in single working steps without increasing the number of steps required
3Volume of stationary object
If high packing density is used in vehicle batteries, then space efficiency is improved, but connecting surface area becomes large while space for tools becomes limited
Solution Approach 1:
The patent resolves the space conflict by utilizing the third dimension - connecting tabs are folded perpendicular to the cell stack surface, allowing electrical connections to be made laterally rather than requiring additional horizontal or vertical space in the densely packed battery configuration
4Temperature
If solid ultrasonic welding tools are used, then thermal dissipation is improved, but tool accessibility to terminal tabs is reduced
Solution Approach 1:
By orienting connecting tabs perpendicular to the cell stack surface, the patent allows solid welding tools to approach terminal tabs from lateral directions with better thermal management, rather than requiring thin-walled tools that compromise thermal dissipation
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 system improves accessibility and allows for cost-effective, high-current connections with reduced heat input, enabling efficient welding of galvanic cells, including those thicker than 7 mm, and eliminates the need for bimetal contacts, while maintaining tool durability and efficiency.
Implementation Method 1
the terminal tabs are attached by way of example by ways of laser welding or ultrasonic welding
Data Source
AI summary
A cell connector to connect a plurality of galvanic cells, system comprising a plurality of galvanic cells, and a method to connect a plurality of galvanic cells. The the cell connector including a longitudinal, planar base section having opposite-lying first and second longitudinal edges. A planar, first connecting tab is connected to the base section on the first longitudinal edge thereof, the plane of the first connecting tab being aligned at a right angle to the base section. A planar, second connecting tab is connected to the base section on the second longitudinal edge thereof, the plane of the second connecting tab being aligned at a right angle to the plane of the base section.