Three-Dimensional Electrode Terminal for Pouch Battery
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Solution Overview
Problem
Pouch-shaped batteries with plate-shaped electrode terminals face challenges in electrical connection due to low mechanical strength and complex manufacturing processes, especially when stacked to form battery modules, requiring additional mounting members that increase size and complexity.
Innovation Solution
A three-dimensional electrode terminal with a predetermined thickness and perpendicular surface is designed to facilitate easier electrical connections and enhance mechanical strength, allowing for stable coupling without modifying the terminal shape, using methods like die casting and bending to form the terminal in a three-dimensional structure with features like through-holes and protrusions for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plate-shaped electrode terminals are used in pouch-shaped batteries, then the batteries can be manufactured with low costs and high integration, but the electrical connection becomes difficult and requires skilled techniques with complicated manufacturing processes
Solution Approach 1:
The electrode terminal is transformed from a two-dimensional plate shape to a three-dimensional structure by extending it in the thickness direction. This dimensional change creates a perpendicular surface that simplifies the connection process, allowing direct welding or mechanical coupling without requiring the terminal to be bent during assembly.
Solution Approach 2:
The perpendicular surface is pre-formed on the electrode terminal during the battery manufacturing process, before the connection step. This preliminary formation of the connection surface eliminates the need for skilled bending operations during assembly and simplifies the overall manufacturing process.
2Reliability
If plate-shaped electrode terminals are bent to create perpendicular surfaces for connection, then electrical connection can be achieved, but the manufacturing process becomes complicated and requires skilled techniques
Solution Approach 1:
Instead of bending the plate-shaped terminal in the plane direction, the invention extends the terminal in the thickness direction to create a perpendicular surface. This dimensional change maintains reliable electrical connection while eliminating the need for complex bending operations and skilled techniques.
3Strength
If additional mounting members such as cartridges are used to maintain stable coupling of stacked batteries, then mechanical strength is improved, but the assembly process becomes complicated and the overall size increases
Solution Approach 1:
The electrode terminal is designed to serve dual functions: electrical connection and mechanical coupling. By forming a three-dimensional structure with a perpendicular surface, the terminal can directly connect to bus bars or connecting members, providing both electrical conductivity and mechanical strength without requiring separate mounting members like cartridges.
Solution Approach 2:
The three-dimensional electrode terminal structure performs multiple functions simultaneously: it conducts electricity and provides mechanical support for stable coupling of stacked batteries. This multi-functionality eliminates the need for additional mounting members, simplifying the assembly process and reducing overall size.
4Reliability
If through-holes are formed in electrode terminals and additional connecting members are inserted, then interconnection is achieved, but the contacting forces become inconsistent across unit cells causing resistance changes
Solution Approach 1:
The invention removes the through-holes from the electrode terminal structure. By eliminating the through-holes and using a solid three-dimensional terminal with a perpendicular surface, consistent contacting forces are achieved across all unit cells, preventing resistance changes while maintaining reliable interconnection.
Data Source
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AI summary
Disclosed herein is a three-dimensional electrode terminal of a battery having an electrode assembly mounted in a pouch-shaped case, wherein a part of the electrode terminal, which is exposed from the battery case, has a predetermined thickness, and has a perpendicular surface (a perpendicular end surface) formed on the end thereof. According to the present invention, it is possible to easily accomplish the connection between the electrode terminal and the electrically connecting member without modifying the shape of the electrode terminal, and it is possible to easily accomplish the connection for detecting the voltage, the current, and the temperature of the battery. Furthermore, the mechanical strength of the three-dimensional electrode terminal according to the present invention is higher than that of the conventional plate-shaped electrode terminal. Consequently, the stability of the three-dimensional electrode terminal is high in the state that the electrode terminal is electrically connected with the electrically connecting member, and the electrical connection is easily accomplished even in a small space, especially when batteries are stacked one on another with high density so as to manufacture a medium- or large-sized battery module.