Rechargeable Battery Lead Plate 180-Degree Bend

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Solution Overview

Problem

Conventional rechargeable batteries face challenges in manufacturing complexity, high costs, and reduced capacity per volume due to the use of molding resin methods and the 'L'-shaped lead plate configuration, which increases the longitudinal size and compromises insulation and stability.

Innovation Solution

A rechargeable battery design featuring a lead plate bent at 180 degrees to couple the bare cell and protective circuit board in parallel, along with an insulation filling member and a stopper to enhance insulation and stability, and a combining case that simplifies the manufacturing process by eliminating the need for melting resin methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If an 'L'-shaped lead plate is used to connect the bare cell and protective circuit board, then electrical connection is achieved, but the longitudinal size increases and capacity per volume decreases

Engineering Contradiction:

Improvecapacity per volumeVSAvoidlongitudinal size

Core Design Contradiction:

Volume of moving objectVSLength of moving object

Solution Approach 1:

The lead plate is bent at 180 degrees to change its spatial configuration from a linear 'L'-shape to a folded configuration. This dimensional change allows the lead plate to connect the bare cell and protective circuit board while reducing the longitudinal distance between them, thereby increasing capacity per volume without compromising electrical connection.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The lead plate is formed with a curved bent shape at 180 degrees instead of a straight configuration. This curvature allows the lead plate to fold back on itself, reducing the overall longitudinal footprint while maintaining the necessary electrical connection path between components.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If molding resin methods are used to attach the protective circuit board, then secure attachment is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveattachment securityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The complex molding resin attachment process is extracted and replaced with a simpler mechanical attachment method. The protective circuit board is directly attached to the bare cell using the bent lead plate structure and additional mechanical fastening elements, eliminating the need for resin molding while maintaining secure attachment.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces expensive and complex molding resin materials with simpler, more cost-effective mechanical attachment components. The bent lead plate structure serves as both an electrical connector and a mechanical attachment element, reducing material costs and manufacturing complexity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Volume of moving object

If the bare cell and protective circuit board are positioned close together, then capacity per volume increases, but insulation and stability deteriorate

Engineering Contradiction:

Improvecapacity per volumeVSAvoidinsulation and stability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

An insulation filling member is introduced as an intermediary element between the bare cell and protective circuit board. This member provides necessary electrical insulation and mechanical stability while allowing the components to be positioned close together, thus increasing capacity per volume without compromising reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Insulation properties are localized to specific areas where needed, such as at the interface between the bare cell and protective circuit board. The insulation filling member is strategically placed only where electrical insulation is required, rather than throughout the entire battery structure, optimizing both insulation effectiveness and space utilization.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8586221B2Rechargeable battery with protective circuit board lead plates connection

Publication Date: 2013.11.19 SAMSUNG SDI CO LTD

AI summary

A rechargeable battery constructed with a bare cell, a protective circuit board electrically connected to the bare cell, a lead plate operationally connecting the bare cell and the protective circuit board, and a combining case covering an upper end of the bare cell, the protective circuit board and the lead plate. The lead plate is constructed with a first plate electrically connected to an outside surface of the protective circuit board, a second plate electrically connected to the bare cell, and an inside bending part connected between the first plate and the second plate. The first plate of the lead plate is bent around the inside bending part at 180 degrees such that the bare cell is coupled with the protective circuit board in parallel. Therefore, the distance between the bare cell and the protective circuit is reduced, and the capacity per volume of the rechargeable battery is increased.