Battery Electrode Terminal Riveting Structure for Low-Resistance Current Paths
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Solution Overview
Problem
Conventional cylindrical battery cells face issues with high inner resistance, heat generation during rapid charging, and inefficient space utilization due to small cross-sectional areas of electrode tabs and leads, which limits energy density and complicates electrical connections.
Innovation Solution
A riveting structure for the electrode terminal is introduced, featuring a body portion, outer and inner flange portions, and a flat portion, with gaskets for insulation, allowing for a larger current path cross-section and improved electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If strip-shaped electrode tabs with small cross-sectional area are used, then the battery structure is simple, but the inner resistance is high and heat generation occurs during rapid charging
Solution Approach 1:
The electrode terminal transitions from a two-dimensional strip-shaped tab to a three-dimensional structure with flange portions extending in multiple directions. The outer flange extends radially outward from the body, while the inner flange extends toward the center, creating a multi-dimensional current collection structure that increases effective cross-sectional area without complicating the overall battery design.
Solution Approach 2:
The electrode terminal employs composite construction by integrating multiple functional portions (body portion, outer flange, inner flange) into a single terminal structure. This composite approach allows different regions of the terminal to serve different functions: the body provides structural support and current collection, while the flange portions provide extended current pathways and connection surfaces, collectively reducing resistance and heat generation.
2Volume of stationary object
If lead wires with small cross-sectional area are used, then the battery assembly is compact, but the current path resistance is high and energy density is limited
Solution Approach 1:
The invention merges the electrode tab and lead wire functions into a single integrated electrode terminal structure. The body portion connects to the electrode assembly while the outer flange serves as the extended current collection surface, eliminating the need for separate lead wires. This integration creates continuous, low-resistance current pathways while maintaining compact battery assembly volume.
Solution Approach 2:
The current path is expanded from a linear one-dimensional path through thin lead wires to a multi-dimensional current collection network. The flange portions create radial and axial current pathways that distribute current flow across larger cross-sectional areas, reducing resistance without increasing the overall battery volume significantly.
3Ease of manufacture
If conventional electrode terminal structure is used, then the manufacturing process is simple, but the electrical connection efficiency is poor and wiring is complicated
Solution Approach 1:
The electrode terminal performs multiple functions within a single component: it collects current from the electrode assembly through the body portion, provides extended current pathways through the flange portions, and offers connection surfaces for both radial and axial wiring configurations. This multi-functionality improves electrical connection efficiency while maintaining manufacturing simplicity through a single integrated part.
4Reliability
If larger current path cross-section is implemented, then the inner resistance decreases, but the space utilization in battery can is reduced
Solution Approach 1:
The terminal structure concentrates the increased cross-sectional area locally at the flange portions where current collection and connection are needed, rather than uniformly increasing the size throughout the battery. The body portion maintains a compact size for efficient space utilization, while the flange portions provide the necessary current path expansion only where required for low-resistance connections.
Data Source
AI summary
The riveting structure of an electrode terminal for a battery includes a battery housing having a bottom; an electrode terminal riveted through a hole formed in the bottom of the battery housing; and a gasket between the electrode terminal and the battery housing. Also, the electrode terminal includes a body portion inserted into the hole; an outer flange portion extending along an outer surface of the bottom of the battery housing from a first side of the body portion exposed through the outer surface; an inner flange portion extending toward an inner surface of the bottom of the battery housing from a second side of the body portion exposed through the inner surface; and a flat portion on the second side of the body portion.