Electrochemical Cell Non-Planar Lead Contact
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Solution Overview
Problem
Existing electrochemical battery cells with pressure contact between an electrode lead and the cell container face challenges in maintaining reliable electrical contact due to variability in manufacturing, requiring tight control of electrode strip thickness and assembly dimensions, which increases complexity and costs.
Innovation Solution
The battery cell design incorporates an electrode lead with an initially non-planar shape that is deformed to facilitate insertion and then springs back to apply pressure against the container side wall, ensuring consistent electrical contact across a wider range of manufacturing tolerances, using shapes like V's and arcs to enhance spring characteristics and tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tight control of electrode strip thickness and assembly dimensions is used to maintain reliable electrical contact, then contact reliability is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The lead is designed with a non-planar shape that can deform dynamically to accommodate dimensional variations in the electrode assembly and container. The lead transitions from a rigid dimensional constraint to a flexible mechanical element that adapts its shape to maintain reliable electrical contact despite manufacturing tolerances, thereby improving contact reliability without increasing manufacturing complexity
Solution Approach 2:
The invention changes the geometric parameters of the lead from a planar configuration to a non-planar configuration with specific curvature characteristics. This parameter change enables the lead to function as a spring element that compensates for dimensional variations, resolving the contradiction between contact reliability and manufacturing complexity by built-in geometric compensation rather than tight dimensional control
2Reliability
If tight control of electrode strip thickness and assembly dimensions is used to maintain reliable electrical contact, then contact reliability is improved, but production costs increase
Solution Approach 1:
The dynamic deformation capability of the non-planar lead eliminates the need for expensive tight tolerance machining and assembly processes. By allowing the lead to flex and adapt to dimensional variations, the invention reduces manufacturing costs while maintaining contact reliability, directly addressing the contradiction between reliability and production cost
Solution Approach 2:
Changing the lead geometry to a non-planar configuration with optimized curvature parameters transforms it into a self-compensating element. This parameter change enables the lead to absorb dimensional variations without requiring expensive precision manufacturing, thereby improving ease of manufacture while maintaining contact reliability
3Ease of manufacture
If the lead is made planar for simple manufacturing, then ease of manufacture is improved, but contact reliability deteriorates due to sensitivity to dimensional variations
Solution Approach 1:
The non-planar lead configuration introduces dynamic deformation capability that compensates for dimensional variations in the electrode assembly and container. This dynamic characteristic maintains reliable electrical contact even when manufacturing tolerances vary, thereby improving contact reliability while preserving ease of manufacture through a relatively simple forming process
Solution Approach 2:
The invention optimizes the geometric parameters of the lead by introducing controlled curvature and non-planar features. These parameter changes enable the lead to function as a mechanical compensator for dimensional variations, resolving the contradiction by achieving both ease of manufacture (through simple forming) and contact reliability (through geometric compensation)
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
This design improves contact reliability, increases manufacturing tolerance, reduces component count, and lowers production costs by maintaining effective electrical contact despite variations in electrode assembly and container dimensions.
Implementation Method 1
the portion of the lead between the electrode assembly side surface and the container side wall comprises a deformed initially non-planar shape that is biased against an internal surface of the container side wall
Data Source
AI summary
An electrochemical battery cell with an electrical lead for electrical contact between one of the cell's electrodes and the side of the cell container. A portion of the lead, disposed between the electrode assembly and the side wall of the container, includes an initially non-planar shape that is in a partially deformed, compressed configuration within the cell to bias the lead against the internal surface of the side wall of the container, thereby applying sufficient force to provide good electrical contact between the electrode and the container. The initially non-planar shape can include one or more V-shaped or arc-shaped grooves, and the grooves can be disposed parallel to a longitudinal axis of the electrode assembly. Also disclosed is a process for making such a cell.