Rechargeable Battery Terminal Flange Surface Welding
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Solution Overview
Problem
Existing rechargeable battery designs face complexities in simplifying the connection process between electrode terminals and lead tabs, which can lead to increased manufacturing costs and potential electrical resistance issues.
Innovation Solution
The rechargeable battery design incorporates a column portion of the electrode terminal inserted into a corresponding insertion portion of the lead tab, with a flange portion welded in a surface contact manner to the inner surface of the lead tab's external circumference, simplifying the connection process and reducing electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional connection method between electrode terminal and lead tab is used, then the connection process becomes complex, but the manufacturing cost increases and electrical resistance issues occur
Solution Approach 1:
The electrode terminal is designed as an integrated structure combining the column portion and flange portion as a single component, eliminating the need for separate connection parts. This merging of functions simplifies the overall connection structure between the electrode terminal and lead tab, reducing manufacturing complexity while maintaining electrical conductivity
Solution Approach 2:
The electrode terminal serves multiple functions simultaneously: the column portion provides mechanical insertion and positioning, while the flange portion provides electrical contact and structural support. This multi-functionality reduces the number of separate components needed, simplifying the connection process and reducing manufacturing costs
2Ease of manufacture
If the connection process is simplified, then manufacturing costs are reduced, but electrical resistance may increase
Solution Approach 1:
By merging the column and flange portions into a single integrated electrode terminal, the invention eliminates additional connection interfaces that would introduce electrical resistance. The direct surface contact between the flange portion and lead tab creates a reliable electrical connection while simplifying the manufacturing process
Solution Approach 2:
The flange portion is designed with optimized dimensions and surface characteristics to ensure low electrical resistance contact with the lead tab. By adjusting the geometric parameters of the flange portion, the invention achieves both simplified manufacturing and reliable electrical conductivity
3Ease of manufacture
If the electrode terminal structure is modified to simplify connection, then manufacturing becomes easier, but connection stability may be compromised
Solution Approach 1:
The electrode terminal employs an asymmetric design where the flange portion has a width greater than the column portion diameter. This asymmetric geometry provides inherent stability by creating a mechanically interlocking connection with the lead tab, preventing displacement while allowing easy assembly. The wider flange portion acts as a stopping feature that ensures proper positioning without requiring complex fastening mechanisms
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 simplifies the connection process between electrode terminals and lead tabs, potentially reducing manufacturing costs and improving electrical efficiency by stabilizing the connection without rotation and minimizing electric resistance.
Implementation Method 1
the lead tab being welded in a surface contact manner to the flange portion along an inner surface of an external circumference of the insertion portion
Data Source
AI summary
A rechargeable battery includes an electrode assembly that performs charging and discharging, a case in which the electrode assembly is installed a cap plate coupled to the case, a lead tab connected to an electrode of the electrode assembly, and an electrode terminal in the cap plate and connected to the lead tab. The electrode terminal includes a column portion inserted into a terminal hole of the cap plate and a flange portion at one end of the column portion, the flange portion being wider than a cross-section of the column portion, and the flange portion being at an inner side of the cap plate. The lead tab includes an insertion portion into which the column portion is inserted, the lead tab being welded in a surface contact manner to the flange portion along an inner surface of an external circumference of the insertion portion.