Foldable Lead Plate Connection for Secondary Battery Terminals
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Solution Overview
Problem
Existing secondary battery manufacturing methods lack a robust and efficient connection structure between the electrode terminal and lead plate, which can lead to instability and reduced performance in lithium secondary batteries.
Innovation Solution
A new connection structure is introduced where a lead plate with foldable regions is used to connect the electrode terminal to a circuit board, employing resistance welding and direct spot welding techniques to secure the connection, utilizing materials like nickel and aluminum for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple connection structure is used between electrode terminal and lead plate, then manufacturing complexity is reduced, but connection strength and reliability deteriorate
Solution Approach 1:
The lead plate is divided into multiple segments including a first lead plate and a second lead plate, allowing each segment to perform specific functions. The first lead plate connects to the circuit board while the second lead plate connects to the electrode terminal, distributing mechanical and electrical stresses across separate components rather than a single monolithic structure.
Solution Approach 2:
The second lead plate is folded back and positioned underneath the first lead plate, creating a nested configuration where the second lead plate is partially embedded within the structure formed by the first lead plate. This nested arrangement maximizes connection strength while minimizing the overall footprint and structural complexity.
2Strength
If resistance welding is used to connect lead plate and electrode terminal, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
Traditional mechanical fastening methods (screws, clips, or adhesive bonding) are replaced with resistance welding, which uses electrical resistance and heat to create metallurgical bonds. This substitution provides superior connection strength and reliability, particularly for withstanding the thermal and mechanical stresses of battery operation, despite requiring more sophisticated manufacturing equipment.
3Strength
If multiple plates are foldably connected, then mechanical reinforcement is improved, but ease of manufacture deteriorates
Solution Approach 1:
The second lead plate is pre-formed with a folded configuration during the manufacturing process, rather than requiring post-assembly folding. This preliminary shaping allows the folded structure to be installed as a single component, maintaining mechanical reinforcement benefits while simplifying the assembly process. The folding is performed at a predetermined location to ensure proper alignment and connection geometry.
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 connection structure provides mechanical reinforcement and improved electrical connectivity, enhancing the stability and performance of secondary batteries by preventing over-charging and over-discharging, thus extending battery life and reliability.
Implementation Method 1
the first and second plates and the electrode terminal may be connected to each other by resistance welding
Implementation Method 2
the first plate may be soldered on the circuit board
Data Source
AI summary
A secondary battery secondary battery includes a bare cell having an electrode terminal, and a protective circuit module having a circuit board and a lead plate. The protective circuit module is electrically connected to the bare cell such that the electrode terminal and the circuit board are connected to each other through the lead plate. The lead plate includes a first plate mounted on the circuit board, and a second plate foldably connected to the first plate.