Cylindrical Cell Terminal-Vent Assembly With Integrated Lead Plate
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Solution Overview
Problem
The existing manufacturing processes for cylindrical secondary cells, such as lithium-ion batteries, face challenges in reducing production time and costs while ensuring safety through complex vent arrangements and multiple parts, which can hinder efficient energy output and increase production complexity.
Innovation Solution
The design integrates a single-piece electrode lead plate with a rivet head that forms part or all of the terminal, incorporating a vent arrangement to reduce the number of parts, enhance energy output, and ensure safety through a simplified assembly process using a mandrel to form the rivet head without requiring complex tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate parts are used for the terminal and vent arrangement, then safety and functionality are ensured, but the number of parts increases leading to higher production time and costs
Solution Approach 1:
The patent combines the terminal and vent arrangement into a single integrated electrode lead plate assembly. The electrode lead plate serves dual functions: as the electrical conductor for current collection and as the structural component containing the vent arrangement. This merging eliminates the need for separate terminal components and vent mechanisms, thereby reducing the total number of parts while maintaining both safety and electrical functionality.
Solution Approach 2:
The electrode lead plate is designed to perform multiple functions simultaneously: it acts as the electrical terminal for current collection, provides structural support at the can end, and incorporates the vent arrangement for safety pressure relief. This multi-functionality reduces component count and simplifies the overall cell construction while ensuring both operational and safety requirements are met.
2Ease of manufacture
If multiple separate parts are used for assembly, then functionality is ensured, but production time and costs increase
Solution Approach 1:
By integrating the terminal and vent arrangement into the electrode lead plate, the patent reduces the number of assembly steps. Instead of assembling multiple separate components (terminal, vent mechanism, lead plate), the manufacturer only needs to install the single integrated electrode lead plate assembly, significantly reducing production time and labor costs.
Solution Approach 2:
The vent arrangement is pre-integrated into the electrode lead plate during manufacturing, so that when the lead plate is installed in the cell, the vent functionality is already in place and requires no additional assembly steps. This preliminary integration of functions into a single component streamlines the production process.
3Reliability
If a complex vent arrangement is used, then safety is improved, but device complexity and production costs increase
Solution Approach 1:
The patent integrates the vent arrangement directly into the electrode lead plate structure. The lead plate itself contains the vent mechanism, eliminating the need for separate complex vent components. This integration maintains safety functionality while simplifying the overall device structure and reducing the number of parts that need to be manufactured and assembled.
4Ease of operation
If multiple separate components are used for the terminal, then functionality is ensured, but the number of parts and production complexity increase
Solution Approach 1:
The patent merges the terminal function and lead plate function into a single integrated component. The electrode lead plate provides both the electrical connection for current collection and the structural terminal interface, eliminating the need for separate terminal components. This reduces the number of parts while ensuring uninterrupted current paths for improved energy output.
Data Source
AI summary
Two cylindrical secondary cells (1) and methods for assembling them, comprising a cylindrical can (2), a terminal (3), and a first conductive sheet (4), with first electrode coating, wound to form a jelly roll (5). The first conductive sheet (4) comprises a portion (4a) free of first electrode coating. An electrically conductive electrode lead plate (6) is arranged in direct contact with at least part of the portion (4a) free of first electrode coating. The electrode lead plate (6) comprises a protrusion (6a) extending through an opening (2c) in the can (2), and the protrusion (6a) comprises a rivet head (6b) on an outside of the can (2). The rivet head (6b) forms at least part of the terminal (3). Alternatively, the electrode lead plate (6) comprises a hollow protrusion (6a) which protrudes through an opening (2c) in the can (2), and the part of the protrusion (6a) which is exposed to the outside of the can (2) comprises a vent arrangement (11).