Button Cell Terminal Plate Structure for Thin, Impact-Resistant Assembly
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Solution Overview
Problem
Existing button cells face challenges in achieving reduced thickness, facilitating bonding between the electrode assembly and the terminal plate, and enhancing impact resistance.
Innovation Solution
The button cell design includes an electrode assembly with a first and second electrode separated by a separator, a case connected to the first electrode, a cap plate covering the outer boundary of the case, a terminal plate connected to the second electrode and bonded to the cap plate, and a bonding layer for insulation and bonding between the cap plate and the terminal plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the button cell structure is simplified to reduce thickness, then the thickness is reduced, but the bonding between electrode assembly and terminal plate becomes difficult
Solution Approach 1:
The patent introduces a bonding layer as an intermediary component between the terminal plate and electrode assembly. This bonding layer facilitates reliable electrical and mechanical connection while enabling a thinner overall structure, as the specialized bonding material can achieve strong adhesion in a thin-film configuration that direct bonding cannot accomplish.
Solution Approach 2:
The patent employs composite material structure by combining the terminal plate (conductive material) with a bonding layer (adhesive material) to create a hybrid assembly. This composite approach allows the structure to simultaneously achieve thinness, strong bonding, and electrical conductivity - properties that single materials cannot provide alone.
2Length of moving object
If the button cell structure is simplified to reduce thickness, then the thickness is reduced, but the impact resistance deteriorates
Solution Approach 1:
The patent uses composite material construction where the bonding layer is made from materials with specific mechanical properties that provide both adhesion and impact absorption. This layered composite structure distributes impact forces across multiple interfaces and materials, achieving high impact resistance in a thin overall configuration.
Solution Approach 2:
The bonding layer serves as a pre-designed cushioning element between the rigid terminal plate and electrode assembly. This intermediate layer is specifically positioned to absorb and dissipate impact energy before it can propagate through the entire battery structure, providing built-in protection against mechanical shocks.
3Ease of manufacture
If a bonding layer is added to facilitate bonding, then the bonding is improved, but the thickness increases
Solution Approach 1:
The patent applies parameter changes by utilizing bonding layer materials and processes that achieve maximum bonding strength at minimum thickness. The bonding layer is engineered with specific thickness parameters, material composition, and bonding conditions that optimize the strength-to-thickness ratio, ensuring strong adhesion while minimizing the added thickness.
Data Source
AI summary
A button cell includes: an electrode assembly including a first electrode, a second electrode, and a separator; a case connected to the first electrode, accommodating the electrode assembly, and having an opening exposing the electrode assembly; a cap plate connected to the case to cover an outer boundary region of the opening, and having a penetration hole exposing a central region of the opening; a terminal plate connected to the second electrode, insulated from and bonded to the cap plate, and including a protrusion plate protruding from a rear surface of a main plate in a direction toward the electrode assembly, the main plate covering the penetration hole; and a bonding layer between and insulating the cap plate and the main plate. A front surface of the main plate and a front surface of the cap plate are located at the same plane as each other.