Micro Rechargeable Battery Cap Plate and Terminal Metal Pairing
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Solution Overview
Problem
Existing rechargeable batteries face challenges in achieving high energy density and efficient manufacturing with diverse materials, particularly for ultra-small batteries used in wearable devices.
Innovation Solution
The design incorporates an electrode terminal made of the same metal as the positive electrode current collector, a cap plate made of a different metal from the negative electrode current collector, and a thermal bonding layer that melts at a predetermined temperature to provide insulation and venting in case of overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electrode terminal and cap plate are made of the same metal as their respective current collectors, then electrical conductivity and manufacturing efficiency are improved, but material compatibility and safety under thermal stress deteriorate
Solution Approach 1:
The patent applies different material properties to different components: the electrode terminal uses the same metal as the positive electrode current collector for optimal conductivity, while the cap plate uses a different metal (stainless steel or nickel) to provide thermal stability and prevent short circuits. This localized differentiation of material properties resolves the contradiction between manufacturing efficiency and material compatibility.
Solution Approach 2:
The battery structure employs composite material construction where the electrode terminal and cap plate are made of different metals (aluminum, stainless steel, or nickel combinations). This multi-material approach allows each component to be optimized for its specific function while maintaining overall system reliability and safety.
2Reliability
If a thermal bonding layer is added between the cap plate and flange portion, then safety and insulation are improved, but device complexity increases
Solution Approach 1:
The thermal bonding layer acts as an intermediary component between the cap plate and flange portion, providing both thermal insulation and mechanical bonding functions. This intermediate layer prevents direct contact between metal surfaces, reducing the risk of short circuits while maintaining structural integrity, thus improving safety without significantly complicating the overall device design.
Solution Approach 2:
The thermal bonding layer changes the thermal and electrical parameters at the interface between the cap plate and flange portion. By introducing a material with different thermal and electrical properties, the layer provides insulation and controlled thermal management, enhancing safety while the bonding function maintains structural simplicity.
3Volume of moving object
If the battery is designed for ultra-small size with high energy density, then portability is improved, but manufacturing precision and material selection constraints worsen
Solution Approach 1:
The battery is segmented into distinct functional components (electrode assembly, electrode terminal, cap plate, case) that can be manufactured separately with optimized tolerances and then assembled. This segmentation allows each component to be produced with appropriate precision levels for its specific function, making ultra-small battery manufacturing more feasible despite the size constraints.
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 configuration enables the production of micro rechargeable batteries with high energy density and enhanced safety features, including rapid gas discharge to prevent explosions.
Implementation Method 1
a thermal bonding layer positioned between the cap plate and the flange portion and insulatingly bonded between the cap plate and the flange portion
Data Source
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AI summary
A rechargeable battery according to an embodiment includes: an electrode assembly including a first electrode, a second electrode, and a separator between the first electrode and the second electrode; a case including an inner space to accommodate the electrode assembly and having an opening at a side thereof; a cap plate coupled to the opening of the case and including a terminal hole to expose the inner space; and an electrode terminal electrically connected to the electrode assembly through the terminal hole and overlapping the cap plate, and the cap plate and the electrode terminal are made of different metals.