Battery Current Collecting Connector Segmentation
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Solution Overview
Problem
Existing methods for connecting metal foil groups to terminals in batteries are cumbersome, prone to bending or rupture, and can lead to unstable connections and internal short-circuits due to improper welding techniques and component placement.
Innovation Solution
The use of first plate portions for positioning and second plate portions for connection, where the protruding ends of metal foil come into contact with the first plate portions and are joined to the second plate portions on outer sides, eliminating the need for inserting components between layers and reducing stress on curved portions, thereby preventing bending and rupture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connecting plate portion is inserted into the core portion of the group of metal foil before welding, then the metal foil can be connected to the terminal, but the metal foil easily bends and ruptures to increase electric resistance
Solution Approach 1:
The current collecting connector is divided into two distinct plate portions: a first plate portion for positioning that contacts the protruding end of the metal foil, and a second plate portion for connection that joins to the metal foil. This segmentation separates the positioning function from the connection function, allowing the metal foil to be positioned without insertion that would cause bending or rupture.
Solution Approach 2:
The first plate portion acts as an intermediary positioning element that contacts the protruding end of the metal foil externally, eliminating the need to insert the connecting plate into the core of the metal foil group. This intermediary structure prevents direct contact between the connecting plate and the metal foil layers during insertion, thereby preventing bending and rupture.
2Productivity
If the current collecting connectors are mounted to the lid plate in advance to form a lid assembly, then the terminal structure is pre-formed, but the connecting plate portions cannot be inserted into the core portions of the groups of metal foil
Solution Approach 1:
By segmenting the current collecting connector into a first plate portion (for positioning) and a second plate portion (for connection), the invention enables the connector to be mounted to the lid plate in advance without compromising future connection capability. The first plate portion provides external positioning that does not require insertion into the metal foil core.
Solution Approach 2:
The current collecting connectors can be preliminarily mounted to the lid plate to form a lid assembly before the power generating element is installed. The first plate portions are positioned to contact the protruding ends of the metal foil, and the second plate portions are positioned for subsequent joining, eliminating the need for insertion at the final assembly stage.
3Ease of manufacture
If the V-shaped connecting portions press or push away the metal foil in the pinching work, then the metal foil can be pinched for welding, but the metal foil easily bends or ruptures to increase electric resistance
Solution Approach 1:
The connector is segmented into a first plate portion for positioning and a second plate portion for connection. The second plate portion is disposed at the outer side of the metal foil group, allowing joining without the need to pinch or press the metal foil from the center, thereby eliminating bending or rupture during the connection process.
Solution Approach 2:
Instead of pinching the metal foil from the center (as in V-shaped connecting portions), the second plate portion joins the metal foil from the outer side. This inverted approach to connection eliminates the pressing action that causes bending or rupture while still achieving secure electrical connection.
4Reliability
If the protruding ends of metal foil are welded to the connecting plate portion, then the connection is formed, but burrs are likely to be formed or metal powder is likely to scatter to cause internal short-circuit
Solution Approach 1:
By separating the positioning function (first plate portion) from the connection function (second plate portion), the welding process can be performed on the second plate portion at the outer side of the metal foil group rather than at the protruding ends. This eliminates the formation of burrs and scattering of metal powder that would occur during welding of protruding ends.
Solution Approach 2:
The connection function is extracted from the protruding ends of the metal foil and transferred to the second plate portion. By taking out the welding operation from the metal foil ends and performing it on the plate portion instead, the harmful effects of burr formation and metal powder scattering are eliminated.
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 approach simplifies the connection process, reduces the risk of metal foil damage, and prevents burrs and internal short-circuits, enhancing the workability and reliability of battery assembly.
Implementation Method 1
first plate portions which respective protruding ends of metal foil of the groups of metal foil come in contact with or close to
Implementation Method 2
the groups of metal foil are joined to the second plate portions
Data Source
Figure 1
Figure 2(a)~3
Figure 4~5
AI summary
It is an object of the present invention to provide a battery in which current collecting connector 2 and 3 and groups 1d and 1e of metal foil of a power generating element 1 can be easily connected, respectively, and a method of manufacturing the same. First plate portions 2b and 3b which respective protruding ends of metal foil of the groups 1d and 1e of metal foil of the power generating element 1 come in contact with or close to and second plate portions 2c and 3c protruding from the first plate portions 2b and 3b toward the power generating element 1 and disposed only at one outer side portions of the groups 1d and 1e of metal foil are provided to the other portions of the current collecting connectors 2 and 3 of the invention and the groups 1d and 1e of metal foil are welded to the second plate portions 2c and 3c.