Rechargeable Battery Lead Tab Welded to Cap Plate

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Solution Overview

Problem

Rechargeable batteries face issues with electrolyte leakage due to the complexity of connections between the cap plate and electrode terminal, requiring multiple parts and gaskets, which increases costs and complexity.

Innovation Solution

A rechargeable battery design that simplifies the connection between the electrode assembly and cap plate using a press-fit method with protrusion and insertion portions, eliminating the need for additional parts and gaskets, thereby preventing electrolyte leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a lead tab and gasket are provided to connect the electrode assembly to the electrode terminal, then electrical connection is achieved, but the number of parts increases and electrolyte leakage risk increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the lead tab and gasket into a single integrated component. The lead tab includes an electrode connecting portion and a terminal connecting portion, where the terminal connecting portion is welded to the cap plate and inherently provides both electrical connection and sealing functions, eliminating the need for a separate gasket and reducing the total number of parts.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The terminal connecting portion of the lead tab serves multiple functions: it provides electrical connection between the electrode assembly and the electrode terminal, and simultaneously acts as a sealing element to prevent electrolyte leakage. This multi-functional design reduces component count while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a gasket is provided between the cap plate and electrode terminal, then electrolyte leakage is prevented, but manufacturing cost increases

Engineering Contradiction:

Improveelectrolyte leakage preventionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The lead tab and gasket are combined into a single component, reducing the number of parts that need to be manufactured, stored, and assembled. This integration lowers manufacturing costs while maintaining the sealing function to prevent electrolyte leakage.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The terminal connecting portion of the lead tab performs both electrical connection and sealing functions, eliminating the need for a separate gasket component. This reduces part count and manufacturing complexity, thereby lowering overall manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If multiple parts are used to connect the cap plate and electrode terminal, then connection reliability is maintained, but assembly complexity increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The lead tab integrates the electrode connecting portion and terminal connecting portion into a single component, reducing the number of assembly steps. The terminal connecting portion is welded to the cap plate in one operation, simplifying the assembly process while maintaining connection reliability.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If a terminal hole is provided in the cap plate for lead tab connection, then electrical connection is achieved, but electrolyte leakage risk increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidelectrolyte leakage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention eliminates the terminal hole from the cap plate by integrating the lead tab connection directly onto the cap plate surface through welding. The terminal connecting portion of the lead tab is welded to the cap plate without requiring a hole, thereby removing the potential leakage path while maintaining electrical connection.

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design reduces the number of parts required, lowers manufacturing costs, and effectively prevents electrolyte leakage by directly connecting the positive electrode current collecting tab to the cap plate without the need for a terminal hole, enhancing the battery's structural integrity and reliability.

Implementation Method 1

The terminal connecting portion may be welded to the cap plate.

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The first protrusion may be forcedly fitted into the insertion hole.

Methodology Applied

Scientific EffectForced fitting: Mechanical Fastener

Data Source

PatentUS10236481B2Rechargeable battery with connected cap plate and current collector

Publication Date: 2019.03.19 SAMSUNG SDI CO LTD

AI summary

A rechargeable battery includes an electrode assembly including first and second electrodes; a case in which the electrode assembly is accommodated; a cap plate combined to the case; an electrode terminal provided in the cap plate and including first and second electrode terminals; and a lead tab including first and second current collecting tabs for electrically connecting the electrode assembly to the electrode terminal, wherein the second current collecting tab includes an electrode connecting portion that is connected to the electrode assembly, and a terminal connecting portion that is bent from the electrode connecting portion and electrically coupled to the cap plate.