Battery Tab Compression Layer for Slim Cell Connection Reliability

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Solution Overview

Problem

Existing battery technologies face challenges in ensuring reliable electrical connections between core cells and electrode tabs, which can lead to instability in charging and discharging processes, particularly in slimmed battery designs where space constraints and external impacts can affect the integrity of these connections.

Innovation Solution

The implementation of a battery design featuring a core cell with conductive compression layers composed of insulating resin and conductive particles, where the electrode tabs have rim portions and protrusion portions that form accommodation spaces, enhancing the electrical and physical coupling between the core cell and electrode surfaces, thereby improving connection reliability and resistance to external impacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a slimmed battery design is used to reduce size, then the battery form factor is improved, but the electrical connection reliability between core cells and electrode tabs deteriorates due to space constraints and external impacts

Engineering Contradiction:

Improvebattery sizeVSAvoidelectrical connection reliability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent employs a composite compression layer comprising conductive particles (such as metal powders) dispersed within an insulating resin matrix. This composite structure enables the layer to simultaneously provide electrical conductivity through the conductive particles and mechanical compression through the resin, thereby maintaining reliable electrical connections between electrode tabs and core cells while accommodating the slimmed battery design constraints

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The compression layer acts as an intermediary substance positioned between the electrode tabs and core cells. It mediates the electrical connection by providing a conductive pathway while also mediating the mechanical stress by distributing external impacts and maintaining constant compression force, thus protecting the electrical connection reliability against external impacts in the slimmed battery structure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the battery is slimmed down to reduce volume, then the form factor is improved, but the resistance to external impacts deteriorates

Engineering Contradiction:

Improvebattery sizeVSAvoidresistance to external impacts

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The compression layer serves as a pre-positioned cushioning element between the electrode tabs and core cells. It is designed to absorb and distribute external impacts before they can reach and damage the electrical connections, providing beforehand protection against harmful forces while maintaining the slimmed battery form factor

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Device complexity

If conventional connection methods are used without compression layers, then the device complexity is reduced, but the electrical connection stability deteriorates leading to charging and discharging instability

Engineering Contradiction:

Improveconnection structure complexityVSAvoidcharging and discharging stability

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The patent changes the physical and electrical parameters of the compression layer by selecting specific conductive particle types, sizes, and concentrations within the insulating resin. By optimizing these parameters, the layer achieves the necessary electrical conductivity and mechanical properties to ensure stable charging and discharging performance while adding minimal structural complexity to the battery design

Inventive Principle:

Principle #35Parameter changes

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 enhances the reliability of electrical connections, reduces electrical resistance, and provides improved resistance to external impacts, ensuring stable charging and discharging performance while maintaining a slimmed battery form factor.

Implementation Method 1

a conductive compression layer between the electrode surface and the electrode tab to form a conductive connection

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

The conductive compression layer includes an insulating resin and conductive particles suspended in the insulating resin

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20230402725A1battery

Publication Date: 2023.12.14 SAMSUNG SDI CO LTD

AI summary

A battery includes: a core cell having a first surface and a second surface opposite to the first surface; an electrode tab including a rim portion forming an accommodation space, the rim portion being conductively connected to an electrode surface formed by at least one of the first surface and the second surface of the core cell, the accommodation space being surrounded along its periphery by the rim portion on the electrode surface; and a conductive compression layer between the electrode surface and the electrode tab to form a conductive connection. The conductive compression layer includes an insulating resin and conductive particles suspended in the insulating resin, and the insulating resin is accommodated in the accommodation space.