Cylindrical Secondary Battery Top-Cap Structure With Same-Side Terminals
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Solution Overview
Problem
The existing structure of cylindrical secondary batteries requires separate components for electrical connection at both the upper and lower portions, complicating the electrical connection and increasing the number of components needed for insulation and waterproofing, which is inefficient.
Innovation Solution
A secondary battery design where the positive and negative electrode terminals are positioned in the same direction, with a top cap serving as a positive electrode terminal and integrally coupled with a conductive washer, eliminating the need for a separate connection plate and reducing component resistance through direct welding of the electrode tab to the top cap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the positive electrode terminal and negative electrode terminal are positioned at opposite positions (upper and lower portions), then the electrical connection structure becomes complicated and requires more components for insulation and waterproofing, but this traditional structure is easy to manufacture
Solution Approach 1:
The patent merges the positive electrode terminal (top cap) and negative electrode terminal (conductive washer) into the same direction (upper portion), eliminating the need for separate connection components at both upper and lower portions. This consolidation reduces device complexity by integrating terminal functions into a single directional arrangement.
Solution Approach 2:
The top cap structure is designed to serve multiple functions: it acts as the positive electrode terminal, provides structural support, and integrates with the conductive washer to form the negative electrode terminal. This multi-functionality reduces the number of separate components needed, simplifying the overall electrical connection structure.
2Reliability
If separate components are used for electrical connection at both upper and lower portions, then the electrical connection is ensured, but the number of components for insulation and waterproofing increases
Solution Approach 1:
The patent combines the terminal functions into a single upper-directional arrangement, reducing the number of separate insulation and waterproofing components needed. By eliminating lower-portion terminals, fewer sealing elements and insulators are required, thus reducing component quantity while maintaining connection reliability.
Solution Approach 2:
The invention extracts and removes the lower-portion electrical connection components entirely, keeping only the upper-portion terminals. This extraction eliminates the need for corresponding insulation and waterproofing components at the lower portion, reducing the total number of parts while preserving essential electrical connection functions.
3Reliability
If a separate connection plate is used to weld the electrode tab, then the electrical connection is secure, but the component resistance increases and energy density decreases
Solution Approach 1:
The patent removes the separate connection plate from the structure, allowing the electrode tab to be welded directly to the top cap. This elimination of the intermediate connection plate reduces the number of welding joints and contact interfaces, thereby reducing component resistance and improving energy efficiency.
Solution Approach 2:
The invention merges the electrode tab welding directly onto the top cap structure, eliminating the separate connection plate. This direct welding creates fewer electrical interfaces and reduces contact resistance, improving energy density while maintaining secure electrical connection through the integrated design.
Data Source
AI summary
A secondary battery includes an electrode assembly having a first electrode tab and a second electrode tab, a battery can electrically connected to the second electrode tab and having an opening portion accommodating the electrode assembly, a top cap covering the opening portion of the battery can and electrically connected to the first electrode tab, a conductive washer electrically connected to the battery can and adjoining a peripheral portion of the opening portion, and an insulative member provided between the top cap and the battery can and the conductive washer electrically connected to the battery can, the insulative member being configured to electrically insulate the top cap and at least one of the battery can and the conductive washer. The top cap includes first and second surfaces facing each other, the second surface having a protruding portion exposed through a hole formed in a central portion of the conductive washer.