Battery Current Collector Protrusions for Bent Electrode Connection
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Solution Overview
Problem
In existing battery designs, the outermost negative electrode plates with a bent shape struggle to connect effectively to the current collector due to their shape, leading to increased manufacturing costs and complexity from the use of brazing materials and time-consuming reflow processes.
Innovation Solution
The battery design features a current collector with an inside part and outermost parts that protrude to accommodate the bent outermost electrode plates, allowing connection through melted portions of the collector joint part itself, eliminating the need for brazing materials and reducing the collector joint size, thereby reducing manufacturing costs and improving connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the outermost first electrode plates are designed with a bent shape, then the battery size can be reduced, but the connection to the current collector becomes difficult and reliability decreases
Solution Approach 1:
Instead of making the electrode plates reach the current collector, the current collector is extended to reach the electrode plates. The protruding parts of the current collector are positioned to contact the joint ends of the outermost electrode plates, reversing the conventional approach and solving the connection difficulty caused by bent electrode plates
Solution Approach 2:
The protruding parts of the current collector serve as an intermediary element between the current collector body and the outermost electrode plates. These protrusions make contact with the joint ends of the bent electrode plates, facilitating reliable electrical connection without requiring the electrode plates to reach the current collector
2Reliability
If brazing material is used to connect electrode plates to current collector, then connection reliability improves, but manufacturing cost and process time increase
Solution Approach 1:
The brazing material is completely removed from the connection system. The invention achieves reliable connection through direct physical contact between the protruding parts of the current collector and the joint ends of the electrode plates, eliminating the need for additional joining materials and complex brazing processes
Solution Approach 2:
The current collector's protruding parts automatically make contact with the joint ends of the electrode plates through their own geometric configuration, without requiring external joining materials or complex assembly processes. The structure itself provides the connection function
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 enables efficient connection of the electrode plates to the current collector without additional joining members, reducing manufacturing costs and achieving a more compact battery size while maintaining high connecting reliability.
Implementation Method 1
an energy beam is applied to the inside part and the outermost parts of the current collector from an opposite side from the first electrode plates to melt the inside part and the outermost parts
Data Source
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AI summary
Provided are a low-cost battery in which an outermost first electrode plate is designed to be bent at a bent portion farther from a current collector than its own joint end so that a near portion extending from the bent portion to the joint end is positioned inward in a lamination direction than a distant portion positioned farther from the current collector than the bent portion, and first electrode plates including the outermost first electrode plate are connected to a collector joint part, and a manufacturing method thereof. In the battery of the invention, a negative collector joint part is connected to a negative joint end of an inside negative electrode plate with a fillet formed of metal melted from the negative collector joint part itself and also connected to a negative joint end of an outermost negative electrode plate with a fillet formed of metal melted from the negative collector joint part itself.