Stacked Battery Cell Positioning With Through-Hole Alignment
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Solution Overview
Problem
The existing methods for positioning large-sized battery cells during stacking face challenges with increased misalignment due to angular errors, leading to higher costs and reduced energy density, especially when using clamping fixtures or higher-precision correction platforms.
Innovation Solution
A battery cell structure with through holes and positioning pins is used to align and stack battery cells, followed by cutting off invalid zones after welding, enhancing precision and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If clamping fixtures are used for positioning battery cells, then positioning accuracy is improved, but the occupied volume increases which reduces energy density
Solution Approach 1:
The invention extracts the positioning function from external clamping fixtures and integrates it directly into the battery cell structure through positioning holes and positioning protrusions. This eliminates the need for separate positioning devices that would occupy valuable space, while maintaining high positioning accuracy through the built-in mechanical interlocking features.
Solution Approach 2:
The battery cell structure itself provides the positioning capability through integrated positioning holes and positioning protrusions. The cell serves both its electrochemical function and its positioning function simultaneously, eliminating the need for external positioning devices and maximizing the usable volume for energy storage.
2Manufacturing precision
If higher-precision correction platforms are used, then positioning accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The invention uses simple, easily manufactured positioning holes and positioning protrusions that can be produced through standard manufacturing processes. These features are much cheaper than high-precision correction platforms, and can be integrated into the battery cell manufacturing process without requiring expensive specialized equipment.
Solution Approach 2:
The positioning features are built into the battery cell structure during manufacturing, before the cells are assembled into modules. This preliminary integration of positioning functionality eliminates the need for costly post-assembly alignment operations and high-precision correction platforms.
3Manufacturing precision
If more visual imaging and correction cycles are used, then positioning accuracy is improved, but stacking speed decreases
Solution Approach 1:
The invention replaces complex optical positioning systems with simple mechanical positioning features. The positioning holes and protrusions provide immediate mechanical constraint that guides cell alignment during stacking, eliminating the need for multiple visual imaging and correction cycles, thereby maintaining high stacking speed while ensuring positioning accuracy.
Data Source
Figure 1~2A
Figure 2B~3B
Figure 4A~4B
AI summary
The invention provides a battery cell (20), semi-finished stacked battery cells structure and the positioning method thereof. The battery cell (20) includes a positive and a negative current collector (41, 42), which respectively includes an active material coating zone (411, 421), a glue frame adhering zone (54a, 54b), an electric output zone (413, 423) and a remaining zone considered as invalid zone (22). At least two through holes (23) are located at the invalid zone (22). The battery cells (20) will be positioned by positioning pins (32) inserted into the through holes (23) of a plurality of stacked battery cells (20). After welding the positive and the negative electric output zones (413, 423), the invalid zones (22) are cut to make the energy density be maximized for the stacked battery cells (20).