Integrated Battery Terminal Assembly With Plastic-Welded Insulators
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Solution Overview
Problem
Conventional direct-coupled terminals in secondary batteries face high failure rates due to uncertain adhesion of current collectors and terminal plates during welding, making it difficult to ensure proper attachment, which can lead to welding defects and reduced adhesive force.
Innovation Solution
An integrated terminal design that includes a terminal assembly with a terminal member and insulator, coupled with a cap insulator through inter-plastic welding, eliminating the need for inter-metal welding and reducing the risk of welding failures, and a secondary battery manufacturing method that uses insert-molding to enhance bonding strength and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct-coupled terminal with inter-metal welding is used, then electrical connection is achieved, but welding failure rate increases due to uncertain adhesion between current collector and terminal plate
Solution Approach 1:
The patent changes the material parameters of the welding interface from metal-to-metal (current collector to terminal plate) to plastic-to-plastic (terminal insulator to cap insulator). This parameter change enables the use of inter-plastic welding instead of inter-metal welding, significantly improving welding reliability while simplifying the manufacturing process by eliminating the need for precise metal alignment and complex welding parameter control.
Solution Approach 2:
The patent introduces terminal insulator and cap insulator as intermediary components between the metal parts (current collector/terminal plate). These insulator components serve as mediators that enable reliable welding by providing a plastic-to-plastic welding interface, while also performing their insulating function. The insulators act as the intermediary layer that resolves the adhesion uncertainty problem in direct metal-to-metal coupling.
2Manufacturing precision
If laser equipment is used for inter-metal welding, then welding precision is improved, but production cost increases
Solution Approach 1:
The patent changes the welding interface material parameters from metal to plastic, which fundamentally alters the welding process requirements. Inter-plastic welding can be performed with simpler equipment compared to laser-based inter-metal welding, thereby maintaining adequate welding precision while significantly reducing production costs by eliminating the need for expensive laser equipment.
3Device complexity
If terminal plate covers current collector, then terminal structure is compact, but detection of proper attachment becomes difficult
Solution Approach 1:
The patent uses terminal insulator and cap insulator as intermediary components that are visible and accessible for inspection. These insulator components allow detection of proper attachment status without requiring the terminal plate to be fully removed or disassembled, thus maintaining structural compactness while enabling easier quality inspection compared to direct metal-to-metal attachment where the interface is completely hidden.
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 integrated terminal design reduces welding failures, lowers production costs by avoiding costly laser equipment, and enhances bonding strength through inter-plastic welding, ensuring reliable electrical connections and improved cell performance.
Implementation Method 1
The terminal insulator and the cap insulator may be bonded together by thermal fusion or bonded together by an adhesive.
Implementation Method 2
The terminal insulator and the cap insulator may be bonded together by thermal fusion or bonded together by an adhesive.
Implementation Method 3
The cap insulator may be formed in the cap plate by insert-molding.
Implementation Method 4
The terminal insulator may be formed in the terminal member by insert-molding.
Data Source
AI summary
An integrated terminal includes: a terminal assembly including a terminal member configured to adjoin a sub-plate electrically connected to an electrode assembly of a secondary battery and a terminal insulator that surrounds a side of the terminal member; and a cap insulator extending along a through hole in a cap plate that is coupled to a case that accommodates the electrode assembly and in which the through hole into which the terminal assembly is inserted is formed. When the terminal assembly is inserted into the through hole, the terminal insulator and the cap insulator adjoin each other, and a reinforced material is inserted into at least one of the terminal insulator and the cap insulator.