Battery Pack Lead Plate With Overlapping Metal Layers
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Solution Overview
Problem
Existing battery packs face challenges in achieving stable electrical connections between multiple battery cells, particularly in smaller and thinner devices, where the demand for efficient output and capacity is high, and the need for reduced resistance and increased thickness in lead plates is critical.
Innovation Solution
A battery pack design utilizing a lead plate with overlapping first and second metal layers, where the end portions include only one metal layer for electrode and terminal connections, and the body portion is formed by integrating these layers to enhance adhesion and reduce width, while an insulating material prevents short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead plate uses a single metal layer, then the manufacturing process is simple, but the electrical resistance is high and the connection stability is poor
Solution Approach 1:
The patent combines multiple metal layers (first metal layer and second metal layer) into a single lead plate structure. The first metal layer provides structural support while the second metal layer provides electrical connection functionality, merging structural and electrical functions into one integrated component that improves connection stability without requiring separate parts
Solution Approach 2:
The lead plate uses composite metal layer structure where the first metal layer and second metal layer are made of different materials with complementary properties. The first metal layer (e.g., copper) provides high electrical conductivity, while the second metal layer (e.g., nickel or tin) provides oxidation resistance and solderability, creating a composite structure that optimizes both electrical performance and connection reliability
2Reliability
If the lead plate thickness is increased to reduce resistance, then the electrical connection improves, but the battery pack thickness increases
Solution Approach 1:
The patent merges multiple thin metal layers into a single lead plate structure that provides the electrical performance of a thick single layer without actually increasing the overall thickness. The stacked configuration of first and second metal layers creates parallel current paths that reduce resistance while maintaining a thin profile suitable for compact battery packs
Solution Approach 2:
The patent transitions from a single-dimensional thick lead plate to a multi-layered structure where current can flow through multiple parallel paths in the vertical dimension. This dimensional change allows resistance reduction through increased effective cross-sectional area without proportionally increasing the overall thickness of the lead plate
3Area of stationary object
If the lead plate width is reduced for compact design, then the battery pack size decreases, but the electrical resistance increases
Solution Approach 1:
The patent compensates for reduced lead plate width by utilizing the vertical dimension with multiple stacked metal layers. The effective electrical cross-sectional area is maintained through the cumulative thickness of multiple layers, allowing current to flow through parallel paths in the vertical direction while keeping the horizontal width compact
4Strength
If the end portions include both metal layers, then the adhesion strength increases, but the connection to electrode tabs becomes complex
Solution Approach 1:
The patent applies different metal layer configurations to different regions of the lead plate: the body portion has both first and second metal layers for maximum adhesion strength, while the end portions have only the second metal layer for simplified electrode tab connection. This local differentiation optimizes both adhesion and manufacturability by matching material properties to functional requirements of each region
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
This design ensures stable electrical connections, reduces resistance, and allows for a thinner profile, effectively addressing the need for efficient energy transfer in compact battery packs.
Implementation Method 1
The first and second metal layers are integrated together by at least one of welding or a conductive adhesive
Implementation Method 2
The first and second metal layers are integrated together by at least one of welding or a conductive adhesive
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The present invention relates to a battery pack comprising a plurality of battery cells including electrode tabs; and at least one lead plate including at least two end portions and a body portion between the end portions. The battery pack is characterized in that the lead plate includes a first metal layer and a second metal layer, wherein the first and second metal layers overlap in the body portion, but the end portions include only one of the first metal layer or second metal layer.