Bent Collector Tabs for Battery Assembly and Impact Resistance

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing lithium ion secondary battery assembly process faces poor workability due to the sealing plate obstructing the connection of lead tabs to internal terminals, and the lack of fixation for collector members leads to potential detachment under impact, causing damage to connections between collector members and lead terminals.

Innovation Solution

The battery design includes collector tabs connected to collector members, which are then connected to lead terminals and external terminals fixed to the sealing plate, with the collector tabs being bent to apply a pushing force that keeps the collector members in contact with the sealing plate, preventing detachment and damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the sealing plate is positioned to connect internal terminals, then the connection between lead tabs and internal terminals can be made, but the sealing plate obstructs the assembly process and workability deteriorates

Engineering Contradiction:

Improveworkability during assemblyVSAvoidassembly process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The connection path is segmented into two stages: first connecting lead tabs to collector members, then connecting collector members to internal terminals. This segmentation allows the sealing plate to be positioned without obstructing the initial connection process, improving workability while maintaining connection functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lead tabs are preliminarily connected to collector members before the sealing plate is positioned. This preliminary action allows the connection to be made when the sealing plate is not in the way, and the collector members are subsequently connected to internal terminals after the sealing plate is in place.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If collector members are not fixed to the sealing plate, then assembly is simplified, but collector members detach under impact and connection reliability deteriorates

Engineering Contradiction:

Improveconnection reliability under impactVSAvoidfixation structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The lead tabs are bent into a curved shape that applies continuous pushing force against the collector members. This curvature transforms the linear connection into a self-locking mechanism that maintains contact pressure, preventing detachment under impact without requiring additional fixation structures.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The potential harm of collector members detaching under impact is converted into a benefit by using the bending force of lead tabs. The bent lead tabs actively push collector members against the sealing plate, turning a passive connection into an active self-locking system that improves reliability under stress.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If lead tabs are directly connected to internal terminals, then connection reliability is maintained, but workability deteriorates due to sealing plate obstruction

Engineering Contradiction:

Improveworkability during assemblyVSAvoidconnection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Collector members are introduced as intermediary components between lead tabs and internal terminals. This intermediary allows the lead tabs to be connected to collector members when the sealing plate is not obstructing, and then the collector members are connected to internal terminals, maintaining connection reliability while improving workability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design enhances workability during assembly and improves the reliability of connections between collector members and lead terminals by maintaining contact under impact, reducing the risk of damage and ensuring stable operation.

Implementation Method 1

the electrode body is accommodated inside the battery case while having the pluralities of collector tabs be in a bent state in an inner space defined by the sealing plate

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11342637B2Secondary battery including bent collector tabs between electrode body and sealing plate

Publication Date: 2022.05.24 SANYO ELECTRIC CO LTD

AI summary

A secondary battery including external terminals provided on an outer side of a sealing plate of a battery case, lead terminals provided on an inner side of the sealing plate, the lead terminals connected to the external terminals being fixed to the sealing plate, collector members disposed on the inner side of the sealing plate, the collector members being connected to the lead terminals, and pluralities of collector tabs connected to a positive electrode plate and a negative electrode plate at an end portion of an electrode body. The pluralities of collector tabs are connected to the collector members, and the electrode body is accommodated inside the battery case while having the pluralities of collector tabs be in a bent state in an inner space defined by the sealing plate.