Button Cell Case Layout With Plastic Intermediary Against Welding Heat

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Solution Overview

Problem

Conventional button cells face issues of electrode assembly damage due to welding heat and short circuits, which affect energy density and reliability.

Innovation Solution

A button cell design featuring a plastic auxiliary member that surrounds the electrode assembly, with non-overlapping first and second cases, preventing damage from welding heat and external interference, and ensuring no short circuits occur.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the case and cap plate are welded to connect to the electrode assembly, then electrical connection is achieved, but the welding heat damages the separator and causes short circuit

Engineering Contradiction:

Improveelectrical connectionVSAvoidwelding heat damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A plastic auxiliary member is introduced as an intermediary component between the case and the electrode assembly. This plastic member is thermally insulated and prevents welding heat from directly contacting the separator and electrode assembly, thereby avoiding short circuits while still enabling electrical connection through conductive elements integrated into the plastic auxiliary member.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The case is divided into separate functional zones: a welding area for electrical connection and a protective area for mechanical support. The plastic auxiliary member creates spatial segmentation that isolates the heat-affected zone from the sensitive electrode assembly, allowing welding to occur without damaging the separator.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If the case and cap plate are welded in a compact design, then device size is reduced, but the separator is damaged by welding heat causing short circuit

Engineering Contradiction:

Improvebutton cell sizeVSAvoidseparator integrity

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The plastic auxiliary member serves as a thermal barrier that can be integrated into compact button cell designs. It allows the case to be welded close to the electrode assembly without direct heat contact, maintaining small form factor while protecting separator integrity through its heat-resistant properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Shape

If the first case and second case overlap in the first direction, then structural compactness is improved, but mutual interference and damage occur

Engineering Contradiction:

Improvecase arrangementVSAvoidexternal interference

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The design transitions from overlapping cases in the first direction to a side-by-side arrangement where the first case and second case are positioned adjacent to each other without overlap. This dimensional reconfiguration eliminates mutual interference while maintaining structural compactness through optimized spacing and the plastic auxiliary member's support structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP4632886A1Button cell

Publication Date: 2025.10.15 SAMSUNG SDI CO LTD

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AI summary

The invention concerns a button cell (1000) that includes an electrode assembly (100) and two cases (300, 400) housing the electrode assembly (100). To reduce the effort for producing the button cell (1000) that conventionally required welding the cases (300, 400) to each other, the button cell (1000) comprises a plastic auxiliary member (200) interconnecting the cases.