Battery Tab Riveting Structure for Slag-Free Terminal Connection
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Solution Overview
Problem
Conventional methods for connecting tabs to terminal posts in lithium-ion batteries result in reduced energy density, safety risks due to welding slag, and tab cracking, leading to increased production costs and decreased yield rates.
Innovation Solution
A riveting method is employed to connect tabs and terminal posts without using transfer sheets, utilizing rivets that penetrate through riveting holes in the tabs to secure them to the terminal posts, forming an integral connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding methods (ultrasonic welding or laser welding) are used to connect tabs to terminal posts, then connection strength is improved, but welding slag is generated causing safety risks and tab cracking occurs reducing yield rate
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical energy field) with a mechanical riveting process. The rivet is inserted through the tab and deformed to create a mechanical connection with the terminal post, eliminating the need for welding and avoiding welding slag and tab cracking issues.
Solution Approach 2:
The rivet serves as an intermediary component between the tab and terminal post. Instead of directly welding the tab to the terminal post, the rivet mediates the connection by being inserted through the tab and deforming to create a secure mechanical bond with both components.
2Reliability
If transfer sheets are used to connect tabs to terminal posts, then connection reliability is improved, but battery weight increases and energy density decreases
Solution Approach 1:
The patent extracts and eliminates the transfer sheet component from the connection system. The rivet directly connects the tab to the terminal post without requiring an intermediate transfer sheet, thereby reducing battery weight and improving energy density while maintaining connection reliability.
Solution Approach 2:
The patent merges the functions of the transfer sheet and the connection mechanism into a single integrated rivet structure. The rivet simultaneously provides mechanical support, electrical connection, and structural bonding that were previously distributed across multiple components.
3Weight of moving object
If riveting method is used to connect tabs to terminal posts without transfer sheets, then battery weight is reduced and energy density is improved, but connection strength may be compromised
Solution Approach 1:
The patent changes the physical state and geometry parameters of the rivet during the connection process. The rivet transitions from a cylindrical insert to a deformed structure with expanded diameter, creating a mechanical interlock that provides strong connection while maintaining lightweight construction.
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 approach reduces battery weight, enhances energy density, improves safety by avoiding welding slag, and addresses tab cracking, thereby increasing yield rates and lowering production costs.
Implementation Method 1
A rivet is connected to the terminal post and penetrates through the riveting hole to rivet the terminal post and the tab
Data Source
AI summary
A secondary battery, a battery pack, and an electronic device is provided. The secondary battery includes a top cover, a terminal post disposed on the top cover, an electrode assembly, and a rivet. The electrode assembly includes a cell body and a tab protruding from the cell body. A riveting hole is provided on the tab. The rivet is connected to the terminal post and penetrates through the riveting hole to rivet the terminal post and the tab.