Secondary Battery Terminal Protrusion for Stable Module Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Secondary batteries face limitations in increasing size and length, which affects their output and stability, particularly when multiple batteries are connected in series or parallel, as existing terminal connections via welding can be unreliable and difficult to manage.
Innovation Solution
The design includes a secondary battery with protrusions on the terminals that allow for improved weldability with a busbar, featuring a first terminal plate and a protrusion that can be bent, with a guide hole and welding area, enabling secure electrical connections and enhanced energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple secondary batteries are connected to a busbar by welding terminals, then higher output is achieved, but weldability and connection reliability deteriorate
Solution Approach 1:
The terminal is segmented into a terminal plate and a protrusion, where the protrusion serves as a dedicated welding portion. This segmentation allows the welding operation to be performed on a specific, optimized geometry that improves weldability while maintaining the overall terminal function.
Solution Approach 2:
The protrusion is designed with specific local geometric qualities (such as increased surface area, optimized curvature, or enhanced material properties at the tip) that are specifically tailored for welding. This local quality enhancement improves weldability without affecting other parts of the terminal.
2Power
If multiple secondary batteries are connected to a busbar by welding terminals, then higher output is achieved, but manufacturing complexity increases
Solution Approach 1:
The protrusion is pre-formed as an integral part of the terminal structure during terminal manufacturing. This preliminary action eliminates the need for separate welding fixture design and positioning steps, reducing manufacturing complexity while enabling multiple batteries to be connected for higher output.
3Manufacturing precision
If terminal size is increased to improve weldability, then welding quality improves, but battery size limitations are exceeded
Solution Approach 1:
Instead of increasing the overall terminal size in all dimensions, the invention extends the terminal in one specific dimension by adding the protrusion. This dimensional change allows the welding surface area to be increased for better weld quality while keeping the battery's overall size within acceptable limits.
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 weldability and energy density, allowing for more reliable connections between secondary batteries and busbars, improving the stability and output of battery modules by ensuring consistent and high-quality welds.
Implementation Method 1
The busbar is coupled to the first protrusion of the first secondary battery and the second protrusion of the second secondary battery
Data Source
AI summary
A secondary battery includes: an electrode assembly including a first electrode tab and a second electrode tab exposed at opposite sides thereof; a first collector electrically coupled to the first electrode tab; a case having two open sides and accommodating the electrode assembly and the first collector therein; a first cap plate sealing one of the open sides of the case; and a first terminal mechanically and electrically coupled to the first collector and exposed to the outside of the first cap plate. The first terminal includes: a first terminal plate at a side of the first collector; and a first protrusion vertically protruding from a top surface of the first terminal plate to the outside of the first cap plate.