Modular Battery Terminal Assembly for Versatile Cap Plate Bonding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing secondary batteries require diverse cap plate-terminal bonding structures due to varying sizes and shapes, necessitating complex and costly manufacturing processes.

Innovation Solution

A modular terminal assembly is introduced, comprising a top surface joint portion, a bottom surface joint portion, a terminal plate, and an insulator, which is easily assembled into a cap plate's accommodating hole, ensuring electrical insulation and seamless integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If diverse cap plate-terminal bonding structures are used to accommodate varying battery sizes and shapes, then adaptability is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveadaptability to varying battery sizes and shapesVSAvoidcomplexity of cap plate-terminal bonding structures

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cap plate is designed with a universal terminal accommodating hole structure that can accommodate terminals of various sizes and shapes through a standardized interface. The hole is configured to receive different terminal configurations (protruding from one side or both sides) without requiring different bonding structures, thus achieving adaptability while maintaining structural simplicity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The terminal accommodating hole is segmented into distinct functional zones: a first portion extending in a first direction and a second portion extending in a second direction. This segmentation allows the single hole structure to accommodate terminals protruding from different sides of the cap plate, providing versatility without increasing overall structural complexity.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If diverse cap plate-terminal bonding structures are used to accommodate varying battery sizes and shapes, then adaptability is improved, but manufacturing cost increases

Engineering Contradiction:

Improveadaptability to varying battery sizes and shapesVSAvoidmanufacturing cost of cap plate-terminal bonding structures

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single universal terminal accommodating hole design serves multiple terminal configurations, eliminating the need to manufacture different bonding structures for different battery types. This reduces manufacturing tooling costs, simplifies production processes, and lowers overall manufacturing expenses while maintaining adaptability across various battery sizes and shapes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The segmented structure of the terminal accommodating hole (first portion and second portion) is integrated into a single cap plate component, allowing mass production through conventional manufacturing processes. The segmentation provides functional versatility without requiring multiple separate parts, thereby reducing assembly steps and manufacturing costs.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If complex cap plate-terminal bonding structures are used, then adaptability is improved, but production time increases

Engineering Contradiction:

Improveadaptability to varying battery sizes and shapesVSAvoidproduction time of secondary batteries

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The universal terminal accommodating hole structure allows terminals of different configurations to be installed using the same bonding process and parameters. This eliminates the need for retooling or adjusting manufacturing processes for different battery types, thereby reducing production time and increasing productivity while maintaining adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The segmented terminal accommodating hole (with first and second portions) is designed to receive terminals in a single bonding operation. The segmentation enables flexible terminal positioning without requiring multiple bonding steps, thus reducing production time while accommodating various terminal configurations.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250357647A1Secondary battery with modular terminal assembled and method of manufacturing the same

Publication Date: 2025.11.20 SAMSUNG SDI CO LTD

AI summary

A secondary battery including a case with an opening, an electrode assembly accommodated in the case, and a cap assembly having a cap plate joined to the opening of the case, the cap plate including a terminal accommodating hole, and a terminal module electrically connected to the electrode assembly, the terminal module having a top surface joint portion insertable into the terminal accommodating hole of the cap plate, the top surface joint portion being joined to a top surface of the cap plate and having an internal through-hole space, a bottom surface joint portion inserted into the terminal accommodating hole and joined to a bottom surface of the cap plate, a terminal plate in the internal through-hole space of the top surface joint portion, and an insulator between the terminal plate and each of the top surface joint portion and the bottom surface joint portion.