Insulated Mandrel Drive Member for Battery Winding
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Solution Overview
Problem
There is a need for improved battery systems for electric vehicles that address the challenges associated with nickel-metal-hydride (NiMH) and lithium-ion batteries, including increased travel distance, performance, and reduced costs, as well as unique manufacturing and temperature regulation challenges specific to lithium-ion batteries.
Innovation Solution
The development of a mandrel for electrochemical cells with an elongated hollow tube and drive members that electrically insulate the tube from the electrode, allowing for efficient winding and assembly of cells, and a method of manufacturing that includes coupling drive elements to the mandrel to form a wound cell element, which can be inserted into a cell housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lithium-ion batteries are used to increase charge density and specific power, then weight and space savings are achieved, but manufacturing challenges and temperature sensitivity increase
Solution Approach 1:
The mandrel is segmented into distinct functional components: an elongated body for structural support and winding, and a drive member for rotation control. This segmentation allows each component to be optimized independently for its specific function, simplifying the manufacturing process while maintaining the high charge density benefits of lithium-ion batteries
Solution Approach 2:
The drive member acts as an intermediary component between the winding mechanism and the mandrel body. It provides electrical insulation while transmitting mechanical rotation, thereby simplifying manufacturing by decoupling the electrical and mechanical functions into separate components
2Power
If lithium-ion batteries are used to achieve higher specific power, then space savings are realized, but temperature regulation challenges increase
Solution Approach 1:
The drive member is extracted as a separate insulating component from the mandrel body, allowing the mandrel to be optimized for thermal management while the drive member handles electrical insulation. This separation facilitates better temperature regulation by enabling independent design optimization for thermal conductivity and electrical insulation
Solution Approach 2:
The mandrel system employs composite material principles by combining conductive materials for the mandrel body (optimized for heat dissipation) with insulating materials for the drive member (optimized for electrical isolation). This composite approach enables simultaneous optimization for both power delivery and temperature regulation
3Productivity
If a mandrel with drive member is used to simplify cell assembly, then manufacturing efficiency is improved, but device complexity increases
Solution Approach 1:
The mandrel combines multiple functions into a single integrated assembly: the elongated body provides structural support and winding surface, while the attached drive member provides rotation control and electrical insulation. This merging reduces the number of separate components and simplifies the assembly process, improving manufacturing efficiency without significantly increasing device complexity
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 solution enables the creation of efficient, cost-effective battery systems that improve the performance and reliability of electric vehicle batteries, allowing for weight and space savings while effectively managing temperature variations and manufacturing complexities.
Implementation Method 1
The drive member is configured to electrically insulate the hollow tube from an electrode that is wound around the hollow tube
Data Source
AI summary
A mandrel for an electrochemical cell includes an elongated hollow tube. At least one drive member is provided at an end of the hollow tube and is configured to receive a driver in order to rotate the mandrel. The drive member is configured to electrically insulate the hollow tube from an electrode that is wound around the hollow tube.