Nested Battery Cell Terminals for Compact Assembly
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Solution Overview
Problem
Conventional battery cells with external terminals occupy significant space, require complex assembly processes, and lack efficient replacement mechanisms, especially in high-reliability applications like electric vehicles.
Innovation Solution
A battery cell design featuring a first terminal arranged within a second terminal, both with screw threads, allowing for compact space usage, easy assembly, and modular replacement, with the option of using different materials like copper and aluminum and incorporating insulators for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If two terminals are arranged on opposing sides of the battery cell, then electrical connection is ensured, but space efficiency is reduced and assembly complexity increases
Solution Approach 1:
The first terminal is arranged inside the second terminal, with the first terminal's outer diameter being smaller than the inner diameter of the second terminal. This nested configuration allows both terminals to occupy the same radial space, significantly reducing the overall space required while maintaining both electrical connections. The assembly process is simplified because both terminals are accessible from the same side of the battery cell.
2Area of stationary object
If terminals are arranged on opposing sides, then electrical connection is maintained, but cooling efficiency and space utilization are compromised
Solution Approach 1:
By nesting the first terminal inside the second terminal, both terminals are positioned on the same side of the battery cell. This configuration frees up the opposite side for cooling functions, such as attaching heat sinks or thermal management components, while both electrical connections remain reliably established through the nested terminal structure.
3Ease of manufacture
If conventional external terminals are used, then manufacturing is straightforward, but space efficiency and replaceability are reduced
Solution Approach 1:
The nested terminal configuration allows both terminals to be manufactured as integrated components, maintaining manufacturing simplicity. The standardized screw thread connections on the outer terminal enable easy assembly and disassembly, facilitating battery cell replacement while maintaining reliable electrical connections throughout the nested structure.
Solution Approach 2:
The terminal system is segmented into an inner terminal and an outer terminal, each with distinct functions. The inner terminal provides one electrical connection while the outer terminal provides another, allowing independent manufacturing and assembly of each component while maintaining overall system reliability and ease of replacement.
Data Source
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AI summary
The invention relates to a battery cell (10) comprising a first terminal (1), which is electrically conductively connected to a first electrode, and a second terminal (2), which is electrically conductively connected to a second electrode, the first terminal (1) being arranged inside the second terminal (2). The invention further relates to a battery module (200) comprising corresponding battery cells (10), to a battery, to a method for producing the battery module (200), and to a use for the battery.