Electrochemical Cell Tab Insulator With Movable Latch
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Solution Overview
Problem
Existing electrochemical battery cell manufacturing methods face challenges with current collecting tabs causing short circuits due to movement and misalignment, especially in hybrid electric vehicles, where mechanical shock and vibration loads exacerbate the issue, and existing insulators struggle to efficiently accommodate multiple tabs and maintain their position during assembly.
Innovation Solution
A tab insulator with a design featuring a plurality of fingers separated by slots, a movable latch, and a robotic system for precise alignment and attachment, along with a device for bending tabs to prevent short circuits by ensuring tabs are securely overlapped and aligned, utilizing a living hinge for flexibility and a rib for robotic installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circular tab insulator with holes is used to prevent short circuits, then short circuit prevention is improved, but the difficulty of accommodating multiple tabs and the complexity of assembly increase
Solution Approach 1:
The insulator is divided into multiple fingers separated by slots, with each finger accommodating a tab individually. This segmentation allows multiple tabs to be handled independently while maintaining insulation, resolving the contradiction between preventing short circuits and simplifying the accommodation of multiple tabs.
Solution Approach 2:
The latch mechanism is designed to be movable, transitioning between a first position for receiving tabs and a second position for securing them. This dynamic feature enables easy assembly and disassembly, reducing assembly complexity while maintaining reliable short circuit prevention.
2Strength
If tabs are made longer to prevent fatigue, then fatigue resistance is improved, but the risk of short circuits due to movement and misalignment increases
Solution Approach 1:
The insulator combines multiple functions: it provides electrical insulation, secures multiple tabs simultaneously, and constrains their movement. By merging these functions into a single component, the design allows tabs to be longer for fatigue resistance while preventing short circuits through the insulator's constraining structure.
Solution Approach 2:
The insulator acts as an intermediary between the tabs and the cell environment, providing a controlled interface that allows tab movement for fatigue resistance while preventing uncontrolled movement that could cause short circuits. The slots and latch mechanism mediate the tab positioning.
3Reliability
If polyimide tape is used to cover tabs, then short circuit prevention is improved, but the protective position is lost during mechanical shock and vibration
Solution Approach 1:
The insulator features a curved ramp that guides tab insertion and provides mechanical engagement. This curved geometry creates a stable mechanical lock that resists displacement during shock and vibration, unlike flat adhesive tape, while maintaining the short circuit prevention function.
4Manufacturing precision
If a robotic system with precise alignment is used for insulator attachment, then assembly precision is improved, but device complexity increases
Solution Approach 1:
The insulator design includes self-aligning features such as the curved ramp and slot geometry that guide tabs into correct positions during insertion. This self-service alignment reduces the need for complex robotic positioning systems, achieving high precision while limiting the increase in device complexity.
Data Source
AI summary
An insulation portion for an electrochemical cell having a plurality of slots into which bent electrode tabs are slid through during an assembly process of an electrochemical cell. A latch is disposed adjacent the slots and is movable from a resting position to a biased position to engage the electrode tabs. Attachment of the insulation portion to the electrochemical cell and bending of the electrode tabs can be robotically performed, such that controllers of an attachment device and bending device are in communication with each other.