Segmented Mandrel for Battery Electrode Assembly
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Solution Overview
Problem
The challenge in producing coiled battery assemblies for medical devices is the difficulty in removing mandrels without damaging the electrode assembly, due to the small size and complexity of components, which can lead to mechanical and electrical coupling issues.
Innovation Solution
The development of mandrels with distinct connector element coupling regions and electrode coupling regions, using different conductive materials such as titanium and aluminum, allows for effective mechanical and electrical coupling, enabling the mandrel to be removed without damaging the electrode assembly by utilizing a removable portion and specific coupling features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If mandrels are used to produce coiled battery assemblies by coupling electrodes around the mandrel, then the electrode assembly can be formed with compact size, but the mandrel removal becomes difficult and may damage the electrode assembly due to small component size and increased assembly complexity
Solution Approach 1:
The mandrel is divided into a core portion and a removable portion that can be separated. The removable portion is designed to be detached after electrode assembly, allowing easy removal without damaging the coiled electrode structure while the core portion remains integrated with the electrode assembly.
Solution Approach 2:
Different portions of the mandrel have different properties - the core portion provides structural support and electrical connection, while the removable portion is designed with specific material properties and geometric features (such as reduced friction surfaces or release agents) that facilitate easy removal after assembly.
2Ease of manufacture
If traditional rod-shaped non-conductive cores are used, then the mandrel can be easily removed, but effective electrical coupling between connector elements and electrodes cannot be achieved
Solution Approach 1:
The mandrel uses composite construction with conductive materials (such as metal coatings or conductive layers) applied to a core structure. This provides both electrical conductivity for reliable coupling between connector elements and electrodes, while the underlying core structure maintains ease of removal capabilities.
Solution Approach 2:
The mandrel acts as an intermediary structure that temporarily holds electrodes and connector elements in position during assembly, then facilitates their separation. The conductive portions enable electrical connection during assembly, while the overall structure allows for controlled disassembly.
3Device complexity
If connector elements and electrodes are coupled to the same mandrel region, then assembly is simplified, but mechanical and electrical coupling issues arise due to material incompatibility and structural interference
Solution Approach 1:
The mandrel has distinct coupling regions - one region for connector elements and another for electrodes. This segmentation allows each region to be optimized for its specific coupling requirements, with appropriate materials and geometric features, without interfering with the other coupling type.
Solution Approach 2:
Different regions of the mandrel have different material compositions and surface properties tailored to their specific coupling functions. The connector element coupling region may have materials optimized for metal-to-metal connection, while the electrode coupling region has properties optimized for adhesive or mechanical bonding to flexible electrode materials.
Data Source
AI summary
A mandrel for use in a battery assembly may include a positive mandrel portion and a negative mandrel portion. Each of the mandrel portions may include a connector element coupling region and an electrode coupling region. The connector element coupling region may be configured to be coupled to a connector element and the electrode coupling region may be configured to be coupled to an electrode.