Cell Stack Spacer Layout for Thickness Variation Absorption
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Solution Overview
Problem
The manufacturing of cell stacks becomes intricate and costly due to the use of two kinds of plate-like spacers made of elastic materials with different thicknesses to absorb variations in the thicknesses of stacked rectangular cells.
Innovation Solution
A cell stack configuration using a combination of first and second intercell members, where the first member includes a plate-like spacer made of hard plastic with a uniform thickness, and the second member does not, arranged at irregular intervals to absorb thickness variations, along with a manufacturing method that determines spacer insertion based on total thickness measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two kinds of plate-like spacers made of elastic material with different thicknesses are used to absorb variations in cell thickness, then the thickness variations are absorbed, but manufacturing becomes intricate and costly
Solution Approach 1:
The patent changes the material parameter from elastic material to hard plastic, and simplifies the thickness parameter from two different thicknesses to a single uniform thickness. This single type of plate-like spacer maintains the ability to absorb thickness variations while dramatically simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The single type of plate-like spacer with uniform thickness serves multiple functions: it acts as a spacer to maintain cell spacing, absorbs thickness variations through selective placement, and provides structural support. This universal component replaces the need for multiple specialized spacers.
2Manufacturing precision
If two kinds of plate-like spacers made of elastic material with different thicknesses are used to absorb variations in cell thickness, then the thickness variations are absorbed, but manufacturing costs increase
Solution Approach 1:
The patent employs inexpensive hard plastic material for the plate-like spacers instead of costly elastic materials. The spacers are simple, disposable components that can be easily manufactured and replaced, significantly reducing the overall manufacturing cost while maintaining functional effectiveness.
Solution Approach 2:
By changing from elastic material to hard plastic and from variable thickness to uniform thickness, the patent reduces material costs and manufacturing complexity. The uniform thickness design allows for standardized production, further reducing costs.
3Manufacturing precision
If plate-like spacers are inserted between all adjacent rectangular cells, then thickness variations are absorbed, but the manufacturing process becomes more complex
Solution Approach 1:
Instead of inserting plate-like spacers between all adjacent cells, the patent applies them selectively only where thickness variations occur. This partial action approach maintains the necessary thickness uniformity while avoiding the complexity of universal spacer insertion, simplifying the assembly process.
Data Source
AI summary
A cell stack includes a plurality of rectangular cells that are stacked and a plurality of intercell members inserted between the adjacent rectangular cells, the cell stack having a rectangular parallelepiped shape. The plurality of the intercell members include: a first intercell member including a plate-like spacer for absorbing variations in thicknesses of the plurality of rectangular cells, and a second intercell member not including the plate-like spacer. The plate-like spacer is made of hard plastic and has a uniform thickness, and the first intercell member and the second intercell member are arranged at irregular intervals.