Cylindrical Lithium Cell Array With Through-Channel Pole Caps
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Solution Overview
Problem
Existing lithium secondary cell designs face limitations in current carrying capacity and efficient cooling, leading to mechanical issues and reduced power performance due to the use of electrode contact pins and complex welding processes.
Innovation Solution
A cylindrical lithium secondary cell array with a winding mandrel and package featuring insulating ceramic material, through-channels, and clamping ring pole caps for efficient cooling and high current capability, along with a fuse element to prevent uncontrolled discharge and corrosion issues in series connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electrode contact pins are used for contacting the winding, then the current carrying capacity is limited, but the device complexity is reduced
Solution Approach 1:
The invention extracts the contacting function from the winding structure by leading out foil strips to the outside, separating the current transport function from the winding package. This allows multiple foil strips to be handled independently, increasing current carrying capacity without complicating the internal winding structure.
Solution Approach 2:
The invention transitions from point-contact (electrode contact pins) to surface-contact (foil strips led out from the winding). By utilizing the dimensional advantage of foil strips with larger surface area, the current carrying capacity is significantly increased while maintaining relatively simple pole cap structure.
2Power
If multiple foil strips are led out from the winding, then the current carrying capacity increases, but mechanical problems such as compression or material breaks occur
Solution Approach 1:
The invention performs preliminary action by providing protective tubes and sealing measures for the foil strips before they are led out from the winding. This prevents mechanical damage during assembly and operation, ensuring reliable current transport while maintaining high current carrying capacity.
3Reliability
If complex welding processes are used for pole cap fixation, then the contacting reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The invention replaces complex welding processes with simpler mechanical fixation methods using pole caps. This eliminates the need for complicated welding technology while achieving sufficient contacting reliability, significantly reducing manufacturing complexity.
4Productivity
If cooling ventilation is added to the cell design, then the charging process can be shortened, but the device complexity increases
Solution Approach 1:
The invention integrates cooling ventilation function into the existing pole cap structure, which already serves for electrical contacting. This multi-functionality approach enables efficient cooling to shorten charging time while avoiding additional complex cooling system components.
Data Source
AI summary
A lithium secondary cell array in a cylindrical design has a winding mandrel and a winding packet, which contains foil-like coated strips and contacting strips that form the electric cell structure consisting of anode, cathode and separator. The cell array has outer electrical connections which include pole caps. The winding mandrel includes an insulating material and has a through-channel extending in the longitudinal axis direction. The winding mandrel is connected to an inner pole cap at each end, the pole caps likewise having a respective through-channel. One outer pole cap having a through-passage is respectively provided, which surrounds the winding packet circumferentially at least in the edge region, wherein several radially arranged force-fit connections, each acting between the outer and the inner pole cap, are used to fix the winding packet and achieve the electrical contacting between the contacting strips and the outer pole cap.