Secondary Battery Connector Protects Welding Surface
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Solution Overview
Problem
Secondary batteries are prone to damage at the welding portion between the current collector and electrode tab due to external vibrations or mechanical shocks, leading to potential separation and reduced functionality.
Innovation Solution
A secondary battery design featuring a connector with a fastening portion, a connecting portion, and a coupling portion, made from materials like polypropylene, polyimide, or polycarbonate, which is fixed to the electrode assembly and fastened to the current collector, distributing the load to the electrode terminal with enhanced coupling strength, thereby preventing damage to the welding surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode tab is directly connected to the current collector, then the electrical connection is simple, but the welding portion is vulnerable to damage from external vibrations and mechanical shocks
Solution Approach 1:
The patent introduces a connector as an intermediary component between the electrode tab and current collector. This connector includes a coupling portion that engages with the electrode tab and a fastening portion that secures to the current collector, thereby protecting the welding portion from direct mechanical stress while maintaining electrical connectivity
Solution Approach 2:
The electrical connection structure is segmented into three distinct components: the electrode tab, the connector (with coupling and fastening portions), and the current collector. This segmentation allows each component to perform its specific function independently, with the connector absorbing mechanical stresses that would otherwise damage the welding portion
2Reliability
If the electrode assembly is secured rigidly to prevent movement, then the welding portion is protected, but the battery cannot accommodate expansion during charging
Solution Approach 1:
The connector is designed with dynamic characteristics that allow it to flex and deform elastically during battery operation. The connecting portion can accommodate the expansion and contraction of the electrode assembly during charging and discharging cycles while maintaining a secure connection and protecting the welding portion from damage
Solution Approach 2:
The connector's physical parameters (such as length, cross-section, and material properties) are designed to change in response to battery expansion. The connector can elongate or compress within elastic limits to accommodate volume changes of the electrode assembly while maintaining structural integrity and protecting the welding connection
3Reliability
If a connector is introduced to protect the welding portion, then the reliability improves, but the manufacturing process becomes more complex
Solution Approach 1:
The connector integrates multiple functions into a single component: it provides mechanical protection for the welding portion, maintains electrical connectivity, and accommodates battery expansion. This merging of functions reduces the number of separate components needed and simplifies the overall assembly process despite the added protection capabilities
Data Source
AI summary
There is provided a secondary battery including a case having an internal space, an electrode assembly inserted into the case and including a first electrode plate, a second electrode plate, and a separator between the first electrode plate and the second electrode plate, an electrode tab electrically connected to the electrode assembly, a cap plate sealing the case, a current collector electrically connected to the electrode tab, an electrode terminal electrically connected to the current collector and configured to pass through the cap plate to protrude toward the outside, and a connector having an end coupled to the electrode assembly and an other end coupled to the current collector.