Stacked Battery Cell Alignment Using Through-Hole Positioning
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Solution Overview
Problem
The existing methods for positioning large-sized battery cells during stacking face challenges such as increased difficulty due to angular errors, leading to edge misalignment and reduced energy density, and higher costs due to the use of high-precision correction platforms or clamping fixtures.
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, thereby improving energy density and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If higher-precision correction platforms are used for positioning battery cells, then positioning precision is improved, but manufacturing cost increases and stacking speed decreases
Solution Approach 1:
Through holes are pre-formed in the current collectors at positions that will align with positioning pins during stacking. This preliminary preparation enables rapid and precise positioning without requiring complex correction platforms during the actual stacking process, thereby maintaining both high precision and fast stacking speed
Solution Approach 2:
Positioning pins are introduced as intermediary elements that fit into the pre-formed through holes to establish precise alignment between stacked battery cells. This simple mechanical intermediary achieves positioning precision without requiring expensive correction platforms, and the direct pin-to-hole fit enables rapid stacking
2Manufacturing precision
If clamping fixtures are used for positioning battery cells, then positioning precision is improved, but energy density decreases due to occupied volume
Solution Approach 1:
The positioning function is extracted from bulky clamping fixtures and implemented through simple through holes in the current collectors and corresponding positioning pins. This removes the need for volume-occupying external fixtures, achieving precise positioning while maximizing the energy density of the assembled battery module
Solution Approach 2:
Through holes are specifically located in the frame zones of the current collectors, which are non-active areas. This local modification enables positioning functionality without interfering with the active material zones, thereby maintaining high energy density while achieving precise positioning
3Manufacturing precision
If the number of visual imaging and correction cycles is increased, then positioning precision is improved, but manufacturing cost increases and stacking speed decreases
Solution Approach 1:
Through holes are pre-formed in the current collectors at positions that will align with positioning pins during stacking. This preliminary preparation enables rapid and precise positioning without requiring multiple visual imaging and correction cycles, thereby reducing both time and cost while maintaining high positioning precision
Data Source
AI summary
The invention provides a battery cell, semi-finished stacked battery cells structure and the positioning method thereof. The battery cell includes a positive and a negative current collector, which respectively includes an active material coating zone, a glue frame adhering zone, an electric output zone and a remaining zone considered as invalid zone. At least two through holes are located at the invalid zone. The battery cells will be positioned by positioning pins inserted into the through holes of a plurality of stacked battery cells. After welding the positive and the negative electric output zones, the invalid zones are cut to make the energy density be maximized for the stacked battery cells.