Battery Tab-to-Terminal Joint Using Conductive Adhesive Buffer

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Solution Overview

Problem

Stress concentration at the connection point between the electrode tab and electrode terminal in batteries can lead to cracks and reduced adhesive strength, affecting conductivity during vibration or dropping events.

Innovation Solution

A battery design incorporating a conductive member, such as an isotropic or anisotropic conductive adhesive, is used to enhance adhesive strength and conductivity by connecting the second electrode tab to a terminal plate with a specific arrangement of the conductive member on the terminal plate, complemented by welding at a different portion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the electrode tab is directly connected to the electrode terminal without additional conductive members, then the structure is simple, but stress concentration occurs at the connection point leading to cracks and reduced adhesive strength

Engineering Contradiction:
Improvestructure simplicityVSAvoidconnection reliability
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

A conductive member is introduced as an intermediary element between the electrode tab and the electrode terminal. This conductive member serves as a mediator that distributes stress across a larger area, preventing stress concentration at the connection point while maintaining electrical conductivity. The conductive member acts as a buffer zone that absorbs mechanical stress during vibration or dropping events, thereby improving connection reliability without significantly complicating the overall structure.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Strength

If the electrode tab connection area is increased to distribute stress, then adhesive strength improves, but the connection area occupies more space affecting battery compactness

Engineering Contradiction:
Improveadhesive strengthVSAvoidbattery compactness
Core Design Contradiction:
StrengthVSVolume of moving object

Solution Approach 1:

The conductive member is designed with localized functionality, concentrating the stress-distribution function in a specific region between the electrode tab and terminal. By placing the conductive member only at the critical connection interface rather than expanding the entire connection area, the solution achieves improved adhesive strength through localized stress management while preserving the compactness of the overall battery structure. The conductive member's small form factor allows it to fulfill its stress-distribution function without significantly increasing the battery volume.

Inventive Principle:
Principle #3Local quality

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 conductive member ensures uniform adhesive strength and conductivity, stabilizing the connection and preventing stress concentration, thereby maintaining electrical performance under various conditions.

Implementation Method 1

a conductive member in a second portion of the terminal plate different from the first portion

Methodology Applied
Scientific EffectAdhesive: Adhesive

Data Source

PatentUS20260031508A1Battery and method of manufacturing the same
Publication Date: 2026.01.29 SAMSUNG SDI CO LTD
  • US20260031508A1 patent drawing
  • US20260031508A1 patent drawing
  • US20260031508A1 patent drawing

AI summary

A battery, including an electrode assembly including a first electrode plate to which a first electrode tab is connected, a second electrode plate to which a second electrode tab is connected, and a separator interposed between the first electrode plate and the second electrode plate, a case accommodating the electrode assembly, the case being connected to the first electrode tab, a cap assembly including a cap plate bonded to an opening of the case and a terminal plate insulated from the cap plate, and connecting the second electrode tab by coming into contact with and being connected to a first portion of the terminal plate facing the electrode assembly, and a conductive member in a second portion of the terminal plate different from the first portion.