Integrated Battery Current Collector for Cap Alignment
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Solution Overview
Problem
The alignment of current collection components with the cap assembly in secondary batteries is challenging, leading to reduced assemblability due to welding issues, making it difficult to correct misalignments in the coupling process.
Innovation Solution
A current collector with an integrated structure featuring electrically insulating substrates and conductive plate members, recessed regions, and securement extensions to improve alignment and assemblability with the cap assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current collection components are welded to thin film tabs separately, then electrical connection is achieved, but alignment precision with cap assembly deteriorates
Solution Approach 1:
The patent merges the current collection component and the insulating substrate into a single integrated structure. The insulating substrate is formed with recessed regions that directly receive and hold the current collection components, eliminating the need for separate welding processes and improving alignment precision with the cap assembly.
Solution Approach 2:
The insulating substrate is pre-formed with recessed regions at specific positions before the current collection components are installed. This preliminary structuring ensures that when the current collection components are placed into the recessed regions, they automatically achieve the correct alignment with the cap assembly, preventing misalignment issues.
2Adaptability or versatility
If current collection components are installed separately, then assembly flexibility is maintained, but assemblability with cap assembly deteriorates
Solution Approach 1:
By integrating the current collection components with the insulating substrate into a unified structure, the patent improves assemblability with the cap assembly. The integrated structure ensures that the connection terminals are precisely positioned, making the assembly process more straightforward and reliable.
3Device complexity
If connection terminals are not precisely aligned, then manufacturing complexity is reduced, but energy density deteriorates
Solution Approach 1:
The insulating substrate is pre-formed with recessed regions that precisely position the current collection components and their connection terminals. This preliminary structuring ensures precise alignment with the cap assembly, improving energy density by enabling more efficient use of battery space and reducing the need for corrective adjustments.
Data Source
AI summary
A current collector for secondary batteries includes at least two electrically conductive current collecting plate members at least partially received in respective recessed regions spaced apart from one another in an electrically insulating substrate. Different interfaces may be provided between the plate members and the substrate. The plate members may be secured to the substrate by adhesive or by insert injection molding when the substrate is formed. A secondary battery including such a current collector has a casing, an electrode assembly, and a cap assembly, where groups of tabs of the electrode assembly are electrically coupled to the current collecting plate members, which are in turn electrically coupled to opposite polarity terminals of the cap.