Secondary Battery Lead Insertion for Internal Volume
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Solution Overview
Problem
Existing secondary battery designs face limitations in increasing battery capacity due to the thickness of the coupled portions of the electrode units, which reduces the internal volume and limits the number of windings of the electrode assembly, thereby restricting the storage of electric charges.
Innovation Solution
The secondary battery incorporates a lead and current collector assembly where the lead is inserted into the current collector with a matching circular shape, forming a welding curve along the boundary, and a stepped structure that reduces the overall thickness, allowing for a larger internal volume and increased battery capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode units are coupled using conventional methods, then the electrical connection is established, but the thickness of the coupled portions increases, reducing the internal volume of the battery case
Solution Approach 1:
The lead is inserted into the accommodation opening of the current collector, creating a nested configuration where one component fits within another. This nesting approach minimizes the overall thickness of the coupled portion while maintaining secure electrical connection between the lead and current collector.
Solution Approach 2:
The invention transitions from a conventional side-by-side or overlapping coupling method to a vertical insertion configuration. The lead extends in the thickness direction and is inserted into the accommodation opening, utilizing the vertical dimension to achieve connection with minimal thickness increase.
2Quantity of substance
If the internal volume is increased to accommodate more windings, then the battery capacity increases, but the coupling structure becomes more complex
Solution Approach 1:
The coupling structure is segmented into distinct functional portions: the lead with base and assembling portion, the current collector with accommodation opening, and the welded joint. This segmentation allows for standardized manufacturing of each component while simplifying the overall assembly process, despite the sophisticated final configuration.
Solution Approach 2:
The invention optimizes geometric parameters of the coupling structure, such as the circular cross-section of the lead and accommodation opening, and the positioning of the base relative to the assembling portion. These parameter optimizations maintain structural integrity while minimizing thickness, enabling volume increase without proportionally increasing complexity.
Data Source
AI summary
A secondary battery includes: a case having an opening; an electrode assembly in the case; a cap plate for sealing the opening of the case; and an electrode unit penetrating through the cap plate, and electrically coupled to the electrode assembly. The electrode unit includes: a current collector coupled to the electrode assembly; and a lead coupled to the current collector and penetrating through the cap plate. The current collector and the lead are coupled to each other by inserting an assembling portion of the lead into an accommodation opening formed in the current collector. Thus, a structure of a coupling portion of the electrode unit for forming charging/discharging paths coupled to the electrode assembly may be improved, and accordingly, an effective internal volume of a case in which the electrode assembly is accommodated and a battery capacity of the electrode assembly may be increased.