Secondary Battery Terminal Alignment via Protrusion-Concave Structure
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Solution Overview
Problem
Existing secondary battery and module designs face challenges in efficient electrical connection and welding processes, particularly in ensuring proper alignment and bonding of terminal plates made from different materials, which can lead to dislocation and reduced welding efficiency.
Innovation Solution
The design incorporates a first terminal plate with a protrusion and a second terminal plate with a concave mounting portion, along with guide portions, to facilitate precise alignment and welding, using insulators and current collectors made from aluminum and copper respectively, and bus bars with distinct parts for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If terminal plates made from different materials (aluminum and copper) are used for first and second electrode plates, then electrical connection efficiency is improved, but alignment precision and welding difficulty deteriorate
Solution Approach 1:
The patent applies different materials (aluminum for first terminal plate, copper for second terminal plate) to different locations based on the electrical connection requirements of each electrode plate. This local differentiation optimizes electrical conductivity while the protrusion-concave mounting structure provides standardized alignment features that compensate for the challenges of working with different materials.
Solution Approach 2:
The mounting portion with concave shape acts as an intermediary structure between the terminal plates and bus bars. This intermediary design provides a standardized interface that facilitates precise alignment and welding, mediating the challenges of connecting different materials (aluminum and copper) to the bus bar system.
2Productivity
If terminal plates with different shapes and materials are used, then electrical connection performance is improved, but welding process complexity increases
Solution Approach 1:
The terminal plate assembly is segmented into distinct components: the terminal plate itself, the mounting portion with concave shape, and the protrusion features. This segmentation allows each component to be optimized for its specific function while simplifying the overall welding process, as the standardized mounting portions provide consistent welding surfaces regardless of the terminal plate material.
3Manufacturing precision
If protrusion and mounting portion structures are added for alignment, then welding accuracy is improved, but device complexity increases
Solution Approach 1:
The mounting portion features an asymmetric concave shape that complements the protrusion on the terminal plate. This asymmetric design provides inherent alignment guidance during assembly, ensuring accurate positioning for welding while adding minimal structural complexity. The asymmetric form fits together like a puzzle, naturally guiding correct alignment.
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 enhances the efficiency and strength of electrical connections between secondary batteries and bus bars, improving the welding process by ensuring accurate alignment and reducing the power required for welding, thereby improving the overall performance and reliability of the secondary battery module.
Implementation Method 1
a first current collector that is integral with the first terminal plate, penetrates through the first insulator, and is bonded to the first electrode plate
Data Source
AI summary
A secondary battery includes an electrode assembly including a first electrode plate, a second electrode plate, and a separator between the first electrode plate and the second electrode plate, a case accommodating the electrode assembly, a cap plate sealing the case, and a first terminal unit and a second terminal unit coupled to the cap plate. The first terminal unit includes a first terminal plate that is electrically connected to the first electrode plate, and the second terminal unit includes a second terminal plate that is electrically connected to the second electrode plate, the second electrode plate having a different shape from the first terminal plate.