Rechargeable Battery Cap Plate Integration
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Solution Overview
Problem
Large-sized rechargeable batteries, such as those for vehicles, face challenges in achieving high energy density and mass production suitability due to existing designs that do not efficiently facilitate current flow and manufacturing complexity.
Innovation Solution
A rechargeable battery design featuring a conductive case with a bottom part and wall part, an electrode assembly with positive and negative electrodes, a cap plate electrically connected to the case, and welding of the positive electrode tab to the bottom part, ensuring efficient current flow and simplified manufacturing through extrusion molding and welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the cap plate length is made longer to accommodate more components, then the battery capacity can be increased, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the positive terminal and negative terminal into a single integrated cap plate structure. The cap plate serves multiple functions simultaneously: it acts as the positive terminal collector, provides structural support, and serves as the sealing surface. This integration eliminates the need for separate component assemblies, thereby increasing battery capacity without proportionally increasing structural complexity.
Solution Approach 2:
The cap plate is designed as a multi-functional component that simultaneously serves as the positive terminal, structural support element, and sealing surface. By making the cap plate universal in its functions, the patent avoids adding separate components for each function, thus increasing battery capacity while keeping the overall structure relatively simple and manageable.
2Quantity of substance
If traditional battery designs are used, then manufacturing processes are established, but energy density and mass production suitability are compromised
Solution Approach 1:
The battery is divided into distinct functional modules: the electrode assembly as one module and the integrated cap plate assembly as another module. This segmentation allows each module to be optimized and manufactured separately using established processes, then assembled together. The electrode assembly can be produced using traditional winding or stacking methods, while the cap plate can be formed using conventional stamping or casting, thereby maintaining manufacturing suitability while achieving higher energy density through optimized component integration.
3Reliability
If the cap plate is made larger to improve electrical connection, then electrical conductivity improves, but the device complexity increases
Solution Approach 1:
The electrical connection function is merged into the cap plate structure itself rather than being a separate component. The cap plate's inherent conductivity and its direct contact with the positive electrode provide reliable electrical connection without requiring additional connection elements. This integration ensures good electrical conductivity while avoiding the complexity that would arise from separate connection components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances energy density by ensuring uniform current flow and simplifies mass production by reducing manufacturing costs and complexity, making it suitable for large-scale production.
Implementation Method 1
The bottom part and the positive electrode tab may be welded to each other
Implementation Method 2
The wall part may be extrusion molded
Data Source
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AI summary
A rechargeable battery includes a conductive case including a bottom part and a wall part extending from a periphery of the bottom part, an electrode assembly including a positive electrode and a negative electrode, and accommodated in the case, a cap plate opposite to the bottom part and electrically connected to the case, a positive terminal fixed to the cap plate and electrically connected to the cap plate, a negative terminal fixed to the cap plate and electrically insulated from the cap plate, a positive electrode tab extending from the positive electrode and electrically connected to the bottom part, and a negative electrode tab extending from the negative electrode, facing the positive electrode tab, and electrically connected to the negative terminal, wherein a length of the cap plate in a first direction is less than a height of the wall part in a second direction.