Button Cell Electrode Tab Coupling Without Upper-Can Welding
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Solution Overview
Problem
Button-type secondary batteries require a separate welding process to couple the first electrode tab to the upper can, complicating the manufacturing process.
Innovation Solution
The first electrode tab is connected to the upper can through a coupling part that engages with a gasket between the lower and upper cans, utilizing the pressure generated when the cans are coupled, eliminating the need for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to couple the first electrode tab to the upper can, then the coupling strength is improved, but the manufacturing process complexity increases due to requiring separate welding equipment and processes
Solution Approach 1:
The patent merges the electrode tab coupling function with the gasket sealing function. The gasket is designed to simultaneously seal the gap between cans and couple the electrode tab to the upper can through integrated coupling portions, eliminating the need for separate welding processes while maintaining coupling strength.
Solution Approach 2:
The gasket serves as an intermediary component that provides both sealing and coupling functions. The coupling portions of the gasket mediate the connection between the electrode tab and the upper can, replacing the welding process with a mechanical coupling mechanism that is integrated into the sealing structure.
2Strength
If welding is used to couple the first electrode tab to the upper can, then the coupling strength is improved, but the manufacturing time increases due to additional welding steps
Solution Approach 1:
The patent combines multiple functions (sealing and coupling) into a single gasket component that is installed in one step. This eliminates the sequential welding process, reducing manufacturing time while maintaining the necessary coupling strength through the integrated design of the gasket's coupling portions.
Solution Approach 2:
The gasket is pre-formed with integrated coupling portions that are designed to automatically couple with the electrode tab during the can assembly process. This preliminary design of the coupling mechanism eliminates the need for subsequent welding steps, reducing overall manufacturing time.
3Strength
If welding is used to couple the first electrode tab to the upper can, then the coupling strength is improved, but the equipment requirements increase due to needing welding devices
Solution Approach 1:
The gasket acts as an intermediary that provides mechanical coupling without requiring welding equipment. The coupling portions of the gasket create a secure mechanical connection between the electrode tab and upper can through press-fit or snap-fit mechanisms, eliminating the need for laser welding devices or other welding equipment.
Solution Approach 2:
The gasket is designed as a simple, inexpensive component that can be easily manufactured and installed without expensive welding equipment. The coupling portions provide sufficient strength for the application while using simpler, more cost-effective materials and manufacturing methods compared to welding.
Data Source
AI summary
A button-type secondary battery includes an electrode assembly; a lower can having an accommodation space in which the electrode assembly is accommodated; an upper can coupled to the lower can to cover the accommodation space; a gasket sealing a gap between the lower can and the upper can and to electrically insulate the lower can from the upper can while being inserted into a coupled portion of the lower can and the upper can; and a first electrode tab including a first coupling part coupled to a first electrode of the electrode assembly and a second coupling part coupled between the gasket, which is disposed at the coupled portion of the lower can and the upper can, and the upper can. The second coupling part is coupled between the gasket and the upper can by a pressure generated when the lower and upper cans are coupled to each other.