Secondary Battery Terminal Plating for Corrosion and Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Secondary batteries experience corrosion and increased weight due to the bulk-type connection structure of current collectors and terminals, which affects electrical conductivity and coupling force, particularly when clad metals with potential differences are used.
Innovation Solution
A secondary battery design featuring a plating on portions of the current collectors and terminals, such as tin, nickel, or zinc, to reduce corrosion and weight by using a semi-hollow structure for the current path components, including current collectors and terminals with cavities and blocking parts, and applying platings on contact areas to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clad metals are used to connect current collector and terminal, then electrical connectivity is achieved, but corrosion occurs at contact area due to potential difference
Solution Approach 1:
A plating layer (such as tin, nickel, or zinc) is applied to the contact surfaces of the current collector and terminal to serve as an intermediary material. This plating prevents direct contact between dissimilar metals, eliminating galvanic corrosion while maintaining electrical conductivity. The plating acts as a protective barrier that mediates the electrical connection without suffering from potential difference-induced corrosion.
Solution Approach 2:
The connection structure uses a composite material approach by combining the current collector, plating layer, and terminal in a multi-material system. Each material is selected for its specific properties: the current collector for electrical conductivity, the plating for corrosion resistance, and the terminal for structural integrity. This composite structure resolves the contradiction by leveraging the strengths of different materials.
2Strength
If bulk-type connection structure is used to connect current collector and terminal, then structural strength is achieved, but weight of secondary battery increases
Solution Approach 1:
The connection structure is segmented into distinct functional components: the current collector, the plating layer, and the terminal. This segmentation allows each component to be optimized for its specific function while reducing overall weight. The plating layer is applied only where needed for corrosion protection, and the connection geometry is optimized to provide sufficient coupling force with minimal material.
Solution Approach 2:
The plating is applied as a thin film on the contact surfaces rather than using bulk materials throughout the entire connection structure. This thin-film approach provides the necessary corrosion protection and electrical conductivity while minimizing the weight of the current path components.
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 solution minimizes corrosion and reduces the weight of the current path, enhancing electrical conductivity and coupling force while maintaining electrical connectivity.
Implementation Method 1
clad metals make contact with and are coupled to other metals, resulting in corrosion at the contact and coupling area due to a potential difference between the metals. The corrosion may be expedited by an electrolyte.
Implementation Method 2
a plating is on a portion of at least one of the first terminal or the first current collector at which the first terminal contacts the first current collector
Data Source
AI summary
A secondary battery is provided including an electrode assembly including a first electrode plate, a second electrode plate, and a separator; a case containing the electrode assembly; a first current collector electrically connected to the first electrode plate; a first terminal electrically connected to the first current collector; a second current collector electrically connected to the second electrode plate; and a second terminal electrically connected to the second current collector, wherein a plating is on a portion of at least one of the first terminal or the first current collector at which the first terminal contacts the first current collector.