Deformable Interconnection Device for Electrochemical Cell Terminals
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Solution Overview
Problem
Existing methods for interconnecting electrochemical cells in batteries for electric or hybrid vehicles require expensive equipment and risk damage during welding, and do not allow for non-destructive dismantling or sufficient mechanical strength and electrical power transmission.
Innovation Solution
A deformable interconnection device with assembly zones and deformation zones that change configuration from an initial state with clearance to an installed state providing electrical contact, allowing for simple installation and uninstallation without expensive equipment, using a metal strip with deformation portions and hinges to ensure secure and efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect interconnection devices to terminals, then electrical contact is improved, but equipment cost increases and risk of cell damage occurs
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical deformation system. The interconnection device uses deformation zones that can be cold-formed to create secure electrical contact through mechanical pressure and geometric interlocking, eliminating the need for welding equipment and associated costs while reducing cell damage risk.
Solution Approach 2:
The patent changes the physical state and geometric parameters of the interconnection device through controlled deformation. The device transitions from a preliminary configuration to a final configured state where deformation zones are cold-formed to specific shapes, creating optimal electrical contact pressure and geometric fit without thermal processes.
2Reliability
If welding is used to connect interconnection devices, then electrical contact is improved, but dismantling becomes destructive
Solution Approach 1:
The patent creates a dynamic, reversible mechanical connection system. The interconnection device can be deformed into place and later deformed back to remove it, allowing non-destructive dismantling and reuse of components. This contrasts with welding which creates permanent bonds requiring destructive removal.
Solution Approach 2:
The patent separates the interconnection function from permanent bonding by using distinct deformation zones that can be independently manipulated. The interconnection device is segmented into functional zones (assembly zones, deformation zones) that allow controlled installation and removal without damaging the cell terminals.
3Ease of repair
If removable systems are used for interconnection, then dismantling is easier, but mechanical strength and electrical power transmission are insufficient
Solution Approach 1:
The patent employs a composite structure combining different material properties within the interconnection device. The device integrates highly conductive materials for electrical contact with mechanically robust deformation zones, creating a composite system that simultaneously achieves excellent electrical conductivity, mechanical strength, and reversibility.
Solution Approach 2:
The patent uses geometric curvature and specific cross-sectional shapes in the deformation zones to enhance mechanical interlocking. The contoured geometry creates friction-based holding forces and geometric constraints that provide high mechanical strength while maintaining the ability to deform for installation and removal.
4Ease of manufacture
If deformation zones are added to the interconnection device, then installation simplicity is improved, but device complexity increases
Solution Approach 1:
The patent divides the interconnection device into distinct functional segments: assembly zones for contact, deformation zones for forming, and connection zones for attachment. This segmentation allows each zone to be optimized independently and simplifies the overall installation process while managing complexity through functional modularity.
Solution Approach 2:
The patent designs the interconnection device with multi-functional zones that perform multiple operations. The deformation zones serve both as structural elements and as the mechanism for both installation (through deformation) and potential removal (through reverse deformation), reducing the need for separate components.
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
Enables easy assembly and disassembly of electrochemical cells with enhanced mechanical strength and electrical contact, reducing the risk of damage and operational costs while maintaining efficient energy storage and transmission.
Implementation Method 1
plastic deformation at room temperature of the at least one first deformation zone, so as to arrange the interconnection assembly in the installed configuration
Data Source
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AI summary
The invention relates to an interconnection assembly (110) of electrochemical cells, comprising: a first (112) and a second (114) cell, each including a terminal (122, 124); and an interconnection device (116, 119). The interconnection device comprises: two assembly zones (130); and a deformation zone (132) disposed between two ends. The interconnection device is deformable between an initial configuration and an installed configuration. In the initial configuration, each of the assembly zones is fitted onto a cell terminal with an initial clearance; and the ends of the deformation zone are at an initial distance (172); and in the installed configuration, each of the assembly zones makes electrical contact with the terminal; and the ends of the deformation zone are at an installed distance (174), which is less than the initial distance.