Side-Terminal Battery Subplate Structure for Lower Connection Resistance
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Solution Overview
Problem
Secondary batteries face performance degradation due to increased component resistance from multiple components such as terminal plates, rivets, and current collectors, which are necessary in conventional side terminal cells.
Innovation Solution
A secondary battery design that eliminates components like terminal plates, rivets, and current collectors by connecting tabs of the electrode assembly to a subplate, which extends through an insulator and cap plate, reducing overall resistance and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple components (terminal plates, rivets, current collectors) are used in conventional side terminal cells, then structural stability is improved, but component resistance increases and performance decreases
Solution Approach 1:
The patent merges multiple components (terminal plate, current collector, and connection elements) into a single integrated subplate structure. The subplate directly connects the electrode tabs and serves as both structural support and electrical conductor, eliminating the need for separate terminal plates, rivets, and current collectors. This integration reduces the number of interfaces and contact points, thereby reducing overall resistance while maintaining structural stability.
2Strength
If multiple components are used in conventional side terminal cells, then structural stability is improved, but device complexity increases
Solution Approach 1:
The subplate integrates multiple functions that were previously performed by separate components: structural support (terminal plate), electrical conduction (current collector), and mechanical connection (rivets). This single integrated component reduces device complexity by eliminating multiple parts and their associated assembly steps.
Solution Approach 2:
The subplate serves multiple functions simultaneously: it provides structural support for the electrode assembly, conducts electrical current from the tabs, and maintains mechanical integrity of the cell. This multi-functionality reduces the number of components needed while maintaining structural stability.
3Reliability
If conventional components and welding processes are used, then connection reliability is improved, but manufacturing cost and production time increase
Solution Approach 1:
The patent extracts and eliminates the welding process from the manufacturing sequence by designing a subplate that can be directly attached to electrode tabs through mechanical means (adhesive bonding or mechanical attachment). This removes the complex welding operation while maintaining reliable electrical and mechanical connections, thereby improving manufacturing efficiency.
4Strength
If multiple components are used in conventional side terminal cells, then structural stability is improved, but manufacturing cost increases
Solution Approach 1:
By merging multiple components into a single subplate, the patent reduces material costs (fewer components to purchase), manufacturing costs (simplified production process), and assembly costs (fewer parts to handle and assemble). The integrated subplate can be manufactured as a single piece, reducing overall manufacturing cost while maintaining structural stability.
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 simplified design reduces component resistance, lowers manufacturing costs, and improves productivity by eliminating the need for welding processes, thereby enhancing the performance of the secondary battery.
Implementation Method 1
the tabs of the electrode assembly are electrically connected to the subplate by laser welding or ultrasonic welding
Implementation Method 2
the tabs of the electrode assembly are electrically connected to the subplate by laser welding or ultrasonic welding
Data Source
AI summary
A secondary battery includes a subplate connected at a first end to a plurality of tabs of an electrode assembly, an insulator coupled to the subplate, and a cap plate configured to receive a bottom portion of the insulator, wherein the subplate extends through the insulator and the cap plate to expose a second end of the subplate is exposed to outside of the secondary battery.