Integrated Current Collector for Rechargeable Battery Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rechargeable battery manufacturing is complicated and costly due to complex assembly processes and contact resistance issues at the electrode terminal and current collector connections.
Innovation Solution
A rechargeable battery design featuring a current collector with a flange part and contacting part integrally formed, allowing for easier manufacturing through a forging process and reduced contact resistance by connecting directly to the active material uncoated parts of the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional multi-component current collector assembly (with separate flange member and lead member) is used, then the structural strength and electrical connection are improved, but the manufacturing complexity and assembly time increase
Solution Approach 1:
The patent combines the flange member and lead member into a single integrated current collector component. This merging eliminates the need for separate assembly steps while maintaining both the mechanical support function (flange) and electrical conduction function (lead member), thereby reducing manufacturing complexity without compromising connection reliability
Solution Approach 2:
The integrated current collector serves multiple functions simultaneously: it provides mechanical support as a flange, conducts electrical current as a lead member, and maintains structural integrity. This multi-functional design reduces the number of components needed while achieving the same overall performance
2Ease of manufacture
If multiple separate components (flange member, lead member, gasket) are assembled together, then the functional requirements are met, but the manufacturing cost and assembly time increase
Solution Approach 1:
By merging the flange member and lead member into one integrated component, the patent reduces the number of assembly operations required. This single-component design eliminates the time-consuming assembly steps of fitting together multiple parts, directly addressing the contradiction between manufacturing simplicity and assembly time
3Strength
If separate flange member and lead member are used, then the structural support is improved, but the contact resistance at connection points increases
Solution Approach 1:
The integration of flange and lead member into a single continuous component eliminates the interface between separate parts. This removes the contact resistance that would exist at the junction of flange and lead member, improving electrical conductivity while maintaining structural support through the unified design
Data Source
AI summary
A rechargeable battery includes an electrode assembly having positive and negative electrodes and a separator interposed between the positive and negative electrodes. Each of the positive and negative electrodes has an active material coated part and an active material uncoated part. A case receives the electrode assembly, the case being provided with an opening through which the electrode assembly is inserted therein. A cap plate is coupled to the opening. An electrode terminal is coupled to a through-hole formed on the cap plate and protrudes out of the case. A current collector has a flange part with a cross-sectional area greater than the through-hole and a contacting part which connects the current collector to the active material uncoated part.