Secondary Battery Collector Plate Protrusion Terminal Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing secondary batteries face challenges in maximizing electrode assembly capacity within a given volume and ensuring reliable connections between collector plates and electrode terminals, leading to inefficiencies in both capacity and structural integrity.
Innovation Solution
The design incorporates a collector plate with a protrusion and an electrode terminal featuring a coupling opening, where the protrusion is engaged and fixed through caulking, and the components are coupled by laser welding, reducing volume occupation and enhancing the secure connection within the battery case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional connection structure between current collector and electrode terminal is used, then the battery can be manufactured with standard components, but the volume occupied by the connection structure is large, reducing the electrode assembly capacity in a given volume
Solution Approach 1:
The current collector is designed with a bent configuration that extends in multiple dimensions. The first current collector bends from vertical to horizontal direction, and the second current collector bends in the opposite direction. This multi-dimensional arrangement allows the connection structure to occupy less volume while maintaining electrical connection functionality, thereby increasing the electrode assembly capacity within a given volume.
Solution Approach 2:
The connection structure is segmented into distinct functional parts: vertical parts for electrical connection to electrode plates, horizontal parts for positioning and coupling, and protrusions for mechanical engagement with terminal coupling openings. This segmentation allows each part to be optimized for its specific function, reducing overall volume while ensuring reliable connection.
2Reliability
If a simple coupling structure between collector plate and electrode terminal is used, then the manufacturing process is simplified, but the connection reliability and structural integrity are reduced
Solution Approach 1:
The coupling mechanism merges multiple functions into a single integrated structure: the protrusion on the current collector serves as both a mechanical engagement feature with the terminal coupling opening and a positioning element during assembly. The bent configuration of the current collector combines electrical connection, mechanical support, and alignment functions in one continuous piece, reducing the need for separate components while enhancing connection reliability.
Solution Approach 2:
The current collector and electrode terminal are designed with composite structural features combining different geometric forms (vertical sections, horizontal sections, bent portions, protrusions) to achieve both simplicity and reliability. The integration of mechanical engagement features (protrusions and coupling openings) with electrical conduction paths creates a composite structure that ensures both structural integrity and electrical connectivity.
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
This configuration increases the electrode assembly's capacity within a given volume and improves the reliability of the secondary battery by simplifying and securing the connection between the collector plate and electrode terminal, reducing the occupied volume and enhancing structural integrity.
Implementation Method 1
The first horizontal part may be coupled to the stepped part by laser welding.
Data Source
AI summary
A secondary battery includes an electrode assembly comprising a first electrode plate, a second electrode plate and a separator located between the first electrode plate and the second electrode plate; a case accommodating the electrode assembly; a cap plate sealing the case; a first collector plate comprising a first vertical part electrically connected to the first electrode plate, a first horizontal part bent from the first vertical part and extending between the electrode assembly and the cap plate, and a first protrusion protruding from the first horizontal part; and a first electrode terminal electrically connected to the first collector plate and extending through the cap plate, wherein the first electrode terminal has a coupling opening engaged with the first protrusion.