Cylindrical Battery Cap Plate Structure for Simpler Bus Bar Connections
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Solution Overview
Problem
Cylindrical secondary batteries face structural complexity and increased manufacturing time due to the insulation and connection of negative and positive electrodes, which complicates the bus bar connection structure when multiple batteries are connected.
Innovation Solution
The design incorporates irregularities on the cap plate to support internal pressure and maintains overall height, with a crimping part of the cylindrical can protruding further downward than the cap plate protrusion, allowing both electrodes to be positioned on the upper surface for simplified bus bar connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a can having a negative electrode and a cap assembly having a positive electrode are insulated from each other by a gasket, then electrical insulation is achieved, but the bus bar connection structure becomes complex and manufacturing time increases
Solution Approach 1:
The patent combines the insulation function and the electrical connection function into a single integrated structure. The cap plate serves both as an insulating element (separating positive and negative electrodes) and as an electrical connection point (providing contact for bus bars to both electrodes). This merging eliminates the need for separate insulation components and simplifies the bus bar connection structure.
Solution Approach 2:
The cap plate is designed to perform multiple functions simultaneously: it acts as a seal for the can, provides electrical insulation between electrodes, and serves as a connection interface for bus bars to both positive and negative electrodes. This multi-functionality reduces the number of components needed and simplifies the overall assembly structure.
2Strength
If irregularities are added to the cap plate to support internal pressure, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The cap plate incorporates curved or domed irregularities instead of flat surfaces. These curved structures naturally distribute internal pressure more effectively across the cap plate surface, enhancing structural strength. The curvature provides inherent pressure support without requiring additional reinforcement components.
Solution Approach 2:
The irregularities are strategically positioned at specific locations on the cap plate where pressure support is most needed. Rather than making the entire cap plate complex, only specific regions are modified with irregularities, maintaining simplicity in other areas while providing targeted structural reinforcement.
3Stability of the object's composition
If the crimping part protrudes further downward than the cap plate protrusion to maintain height, then dimensional stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The crimping part is designed with a predetermined protrusion depth that is greater than the cap plate protrusion from the outset. This preliminary design ensures that even when the cap plate expands under internal pressure, the overall battery height is maintained by the crimping part's extended position, eliminating the need for complex real-time adjustments.
Solution Approach 2:
The design specifies a particular geometric parameter relationship where the crimping part protrusion depth is deliberately set to exceed the cap plate protrusion depth by a specific margin. This parameter change ensures height stability under varying pressure conditions without requiring complex control mechanisms during manufacturing.
Data Source
AI summary
A cylindrical secondary battery includes: an electrode assembly including a positive electrode plate, a separator, and a negative electrode plate; a cylindrical can accommodating the electrode assembly and being electrically connected to the negative electrode plate, a lower end of the cylindrical can being open; a rivet terminal passing through an upper surface of the cylindrical can and electrically connected to the positive electrode plate; and a cap plate sealing the lower end of the cylindrical can, the cap plate having no electrical polarity.