Secondary Battery Tab-to-Terminal Wiring for Higher Energy Density
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Solution Overview
Problem
Existing secondary battery designs face challenges in energy density, manufacturing efficiency, and cost due to the complex connection procedures between the electrode column and top cover plate, which result in reduced space utilization and increased production costs.
Innovation Solution
A secondary battery design featuring a top cover plate made of plastic with an electrode terminal and current collecting wiring board, where the electrode terminal includes a base and extension portion with a specific cross-sectional shape, and a current collecting wiring board with integral connection portions, improving connection stability and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bottom portion of the electrode column is disposed inside the case with certain thickness (1.5 to 4 mm) to connect the electrode terminal to the wiring board, then the connection stability is improved, but the space utilization rate inside the case is reduced and manufacture cost increases
Solution Approach 1:
The patent changes the connection structure from a thick bottom portion extending in the thickness direction to a bent portion extending in the width direction. The bent portion of the tab is bent along the width direction of the top cover plate to connect with the wiring board, eliminating the need for thick bottom portions and optimizing space utilization in the thickness direction.
Solution Approach 2:
The connection structure is divided into distinct functional parts: the bent portion of the tab provides mechanical connection, the wiring board provides electrical connection and routing, and the top cover plate provides structural support. This segmentation allows each component to be optimized independently, reducing overall thickness and improving space utilization.
2Reliability
If the bottom portion is disposed inside the case with larger cross-sectional area to ensure connection stability, then the connection between electrode terminal and assembly is stabilized, but the energy density is reduced due to reduced space utilization
Solution Approach 1:
The connection structure transitions from utilizing the thickness direction (requiring 1.5-4 mm bottom portion) to utilizing the width direction (bent portion extending along width direction). This dimensional change reduces the volume occupied by connection structures, increasing the volume available for active materials and thereby improving energy density while maintaining connection stability.
3Reliability
If complex connection procedures and operations are used between the electrode column and top cover plate, then the connection stability is improved, but the manufacture efficiency is reduced and cost increases
Solution Approach 1:
The patent integrates the mechanical connection function and electrical connection function into a unified structure. The bent portion of the tab serves both as a mechanical anchor and an electrical conductor, eliminating the need for separate connection components and complex assembly procedures, thereby improving manufacturing efficiency while maintaining connection stability.
Solution Approach 2:
The patent extracts the connection function from the bottom portion of the electrode column and relocates it to the bent portion of the tab. This extraction simplifies the overall structure by removing the thick bottom portion and its associated complex connection procedures, reducing manufacturing complexity and cost while maintaining reliable electrical and mechanical connections.
Data Source
AI summary
A secondary battery including: a case including an opening; a top cover assembly including a top cover plate covering the opening and an electrode terminal, the top cover plate including an electrode lead-out hole corresponding to the electrode terminal; an electrode assembly received in the case and including a main body and a tab, the tab being bent relative to a thickness direction of the top cover plate to form a bent portion; and a current collecting wiring board disposed between the top cover plate and the main body and including a first connection portion, a second connection portion, and a transition portion, the first connection portion and the second connection portion extending along a width direction of the top cover plate and being provided opposite to each other, the first connection portion being connected with the electrode terminal, and the second connection portion being connected with the bent portion.