Battery Cell Terminal Assembly for High-Current Sealed Feedthroughs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for terminal assemblies in battery technology that can handle high power transmission efficiently and compactly, particularly for aerospace applications, where existing terminals often struggle with high electrical current densities and temperature stability.
Innovation Solution
The development of a cell terminal assembly with a deformable feedthrough member that secures an electrical connection between inner and outer terminals, providing a high surface area contact and a fluid-tight seal, while supporting high electrical currents and maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional terminals are used for high power transmission, then electrical connection is provided, but the terminals are not compact and cannot handle high current densities effectively
Solution Approach 1:
The feedthrough member is inserted through a feedthrough passage in the outer terminal, with the inner terminal nested within the housing. This nested arrangement allows multiple terminal components to occupy overlapping spatial volumes, achieving high power transmission capability in a compact configuration suitable for aerospace applications
2Power
If existing terminals are designed for high current density, then electrical connection is maintained, but temperature stability and seal effectiveness deteriorate
Solution Approach 1:
The feedthrough member includes a head portion that is deformed to conform to the recess shape, changing the geometric parameters of the connection interface. This deformation creates optimal contact pressure distribution and seal geometry, enabling the terminal to handle high current densities while maintaining temperature stability and effective sealing throughout the operating temperature range
Solution Approach 2:
The feedthrough passage includes a recess that receives the feedthrough member, creating a fluid-tight seal through the deformed head portion. This seal mechanism prevents fluid infiltration at the feedthrough interface, ensuring reliability and temperature stability even when handling high current densities that generate thermal stress
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 terminal assemblies achieve reduced electrical resistance, improved thermal design, and extended temperature operating range, enabling them to handle high current densities and maintain a seal effectively, meeting NASA standards for aerospace applications.
Implementation Method 1
deforming a head portion of the feedthrough member to conform the head portion to a shape of the recess
Implementation Method 2
the deformed head portion providing an electrical connection between the inner terminal and the outer terminal and providing a fluid tight seal between the head portion and the seating surface
Data Source
AI summary
A cell terminal assembly including: an outer terminal configured to be disposed at an external location of a cell, the outer terminal including a feedthrough passage, the feedthrough passage including a recess having a seating surface; and an inner terminal including an electrically inner terminal including a feedthrough member electrically connecting the conductive body to the outer terminal, the feedthrough member including a head portion having a shape that conforms to a shape of the recess and the seating portion and secures the feedthrough member thereto.