Rechargeable Battery Lead Tab Fixing Protrusions

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Solution Overview

Problem

Existing rechargeable batteries face challenges in securely fixing the top cover without additional holders, which increases manufacturing costs and weight, and are prone to contact failures between the lead tab and protective circuit module due to impacts.

Innovation Solution

The rechargeable battery design incorporates a lead tab with fixing protrusions that insert into grooves on the top cover, and buffering members that protrude toward the cap plate to absorb impacts, ensuring stable fixation and preventing contact failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If additional holders are used to fix the top cover, then the fixation stability is improved, but the manufacturing cost and weight increase

Engineering Contradiction:

Improvefixation stabilityVSAvoidbattery weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The lead tab is designed to serve dual functions: electrical connection and mechanical fixation. The fixing protrusions on the lead tab engage with fixing grooves on the top cover, allowing the lead tab to simultaneously provide electrical connectivity and structural stabilization without requiring separate holder components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lead tab is transformed from a single-function electrical connector into a multi-functional component that combines electrical conduction with mechanical fastening capabilities. The buffering members extending from the lead tab provide both electrical buffering and structural support functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If additional holders are used to fix the top cover, then the fixation stability is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvefixation stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fixation function is extracted from the lead tab structure itself through the addition of buffering members and fixing protrusions, eliminating the need for separate holder components. This integration reduces part count and assembly complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If the lead tab is rigidly connected to the protective circuit module, then the electrical connection is improved, but the contact failure risk under impact increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidimpact sensitivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Buffering members are attached to the lead tab and extend toward the cap plate, creating a cushioning structure that absorbs impact forces before they can damage the electrical connection between the lead tab and protective circuit module. This preemptive cushioning protects against potential impact damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The lead tab structure is modified by adding buffering members that change the mechanical properties of the connection, introducing flexibility and shock absorption capabilities while maintaining electrical conductivity. This transforms the rigid connection into a resilient connection.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If buffering members are added to the lead tab, then the impact resistance is improved, but the device complexity increases

Engineering Contradiction:

Improveimpact resistanceVSAvoidlead tab structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The buffering members are designed as flexible extensions of the lead tab that can deform under impact forces, providing shock absorption through elastic deformation. This flexible structure protects the rigid electrical connections while adding minimal structural complexity.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS9397329B2Rechargeable battery having lead tab

Publication Date: 2016.07.19 SAMSUNG SDI CO LTD

AI summary

A rechargeable battery includes an electrode assembly including a first electrode, a second electrode, and a separator, the separator being between the first electrode and the second electrode, a case including a space that receives the electrode assembly therein, a cap plate coupled with an opening of the case, a top cover covering the cap plate, a protective circuit module between the cap plate and the top cover, and a lead tab that electrically connects the protective circuit module and the cap plate. The lead tab includes fixing protrusions and the top cover includes fixing grooves into which the fixing protrusions are inserted.