Serpentine Battery Feedthrough Tab for Space-Efficient Welding
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Solution Overview
Problem
Conventional battery cell feedthroughs require space for a tab to facilitate welding, reducing packaging efficiency and energy capacity due to the need for a working length that occupies volume within the enclosure.
Innovation Solution
A battery cell design incorporating a channel in the feedthrough to house a serpentine tab, which is connected to a pin at one end and the cathode or anode layer at the other, allowing the tab to deform for welding and then return to a compact shape within the channel, thereby minimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional tab is used to facilitate welding, then welding capability is improved, but space within the enclosure is reduced
Solution Approach 1:
The serpentine tab is nested within a channel formed in the feedthrough structure. The tab follows a serpentine path that fits within the confines of the channel, allowing the tab to be contained within the feedthrough volume rather than occupying additional space in the enclosure. This nesting approach resolves the contradiction by providing welding capability through the serpentine tab while confining it to the feedthrough channel space.
Solution Approach 2:
The tab transitions from a conventional straight or simple bent configuration to a serpentine configuration that utilizes three-dimensional space within the channel. By arranging the tab in a serpentine pattern with multiple bends and loops, the effective length of the tab for welding purposes is increased while the projected footprint and volume occupation within the enclosure is minimized. This dimensional optimization allows the tab to achieve sufficient working length without proportionally increasing the space it occupies.
2Ease of manufacture
If a working length of tab is provided for welding, then welding is enabled, but packaging efficiency is reduced
Solution Approach 1:
The serpentine tab is nested within the feedthrough channel, allowing the tab to be contained within the feedthrough assembly rather than extending into the enclosure volume. This nesting eliminates the need to reserve additional space in the enclosure for the tab, thereby improving packaging efficiency while still providing sufficient tab length for welding operations within the channel confines.
Solution Approach 2:
The serpentine configuration allows the tab to achieve sufficient working length by utilizing the channel volume in three dimensions rather than requiring linear extension into the enclosure space. The tab winds through the channel in a serpentine pattern, maximizing the use of available channel volume to provide adequate welding length without proportionally increasing the space occupied in the enclosure, thus improving packaging efficiency.
3Volume of stationary object
If tab space is eliminated, then energy capacity is increased, but welding capability must be maintained
Solution Approach 1:
The serpentine tab is nested within the feedthrough channel, allowing the tab to be contained within the feedthrough assembly rather than occupying additional space in the enclosure. This nesting eliminates the need to allot space within the enclosure to accommodate the tab, thereby increasing the volume available for electrodes and improving energy capacity while still providing sufficient tab length for welding operations within the channel.
Solution Approach 2:
The serpentine configuration allows the tab to achieve sufficient working length by utilizing the channel volume in three dimensions. The tab winds through the channel with multiple bends and loops, maximizing the use of channel volume to provide adequate welding length without requiring additional enclosure space. This enables the enclosure volume to be fully utilized for electrodes, increasing energy capacity while maintaining welding capability through the serpentine tab design.
Data Source
AI summary
The disclosed technology relates to an electrical feedthrough for a battery cell. The electrical feedthrough may include a pin configured to form an external battery terminal, an insulator surrounding the pin and configured to electrically isolate the pin, a channel, and a serpentine tab electrically coupled to the pin at a first end. The serpentine tab is nested within the channel to minimize use of space within an enclosure of the battery cell thereby increasing energy capacity of the battery cell by eliminating the need to allot space within the enclosure to accommodate the tab.