Cylindrical Battery Cell Layout With Straight Connector Path
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Solution Overview
Problem
Cylindrical lithium-ion battery cells face challenges with elevated electrical resistance and increased space requirements due to the need for a bendable metal strip to maintain electrical connection both when the cell is open and closed, which affects energy density and structural size.
Innovation Solution
A battery cell design featuring a straight-line connecting element between the intermediate plate and the end plate, reducing electrical resistance and space requirements, while allowing for electrolyte filling and gas outlet mechanisms to enhance safety and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bendable metal strip is used to maintain electrical connection in both open and closed states, then the electrical connection is maintained, but the electrical resistance increases and space requirement increases
Solution Approach 1:
The electrical connection system is segmented into two distinct states: during assembly (open state) the flexible connector provides mechanical compliance, and during operation (closed state) the rigid rod provides low-resistance electrical connection. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between connection reliability and electrical resistance.
Solution Approach 2:
The flexible connector performs its electrical connection function preliminarily during the assembly phase before the end plate is closed. Once the cell is sealed, this connector is no longer needed for electrical conduction, allowing the primary electrical connection to be established through the rigid rod with superior electrical properties.
2Reliability
If a bendable metal strip is used to maintain electrical connection in both open and closed states, then the electrical connection is maintained, but the space requirement increases
Solution Approach 1:
The connection system is divided into temporary (flexible connector during assembly) and permanent (rigid rod after closure) components. The flexible connector occupies minimal space as it is only needed during the assembly phase, while the compact rigid rod provides the primary connection with minimal space requirement during operation.
Solution Approach 2:
The function of maintaining electrical connection during both open and closed states is extracted from a single continuous component and distributed across two separate components with different geometries and properties, allowing each to be optimized independently for its specific operational phase.
3Loss of energy
If the connecting element extends in a straight line, then the electrical resistance is reduced and space requirement is minimized, but the ability to accommodate both open and closed states is limited
Solution Approach 1:
The system transitions from a static flexible connector that must accommodate both states to a dynamic two-stage system where the connection method changes based on the cell state. During assembly, the flexible connector provides adaptability; during operation, the rigid rod provides optimal electrical performance.
Solution Approach 2:
The flexible connector serves as an intermediary component during the assembly phase, enabling the establishment of electrical connection between components that will later be joined by the rigid rod. This intermediary allows the straight-line rigid rod configuration to be implemented without compromising the ability to accommodate assembly requirements.
Data Source
AI summary
A battery cell is provided. The battery cell has a cell housing with an electrically conductive hollow cylinder; an electrically conductive first end plate closing off the hollow cylinder at one of the end faces thereof; at least one electrode of a first electrical polarity and at least one electrode of a second electrical polarity opposite to the first polarity, and in which the electrodes of different polarities being separated from each other by at least one separator; a first electrically conductive intermediate plate which is arranged between the first end plate and the electrodes and which is electrically insulated from the hollow cylinder; and a connecting element which is electrically connected to the first intermediate plate and the first end plate, the connecting element extending in a straight line between the first intermediate plate and the first end plate.