Prismatic Cell Tab-Through-Cap Terminal Connection Layout

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Solution Overview

Problem

The connection between current collectors and terminal leads in prismatic batteries is prone to stress and detachment due to relative movement during manufacturing and operation, leading to increased packaging requirements and potential disconnection.

Innovation Solution

The method involves disposing current collector tabs through slots in the battery cap and terminal plates, allowing them to be electrically connected at the exterior side, and sealing the enclosure with cover plates to stabilize the connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If current collectors are welded to terminal leads with electrode stacks spread apart or oriented horizontally, then welding access is improved, but current collectors fold or bend causing increased stress and potential disconnection

Engineering Contradiction:

Improvewelding accessVSAvoidconnection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The current collectors are pre-positioned to extend through the cap exterior before welding occurs. This preliminary positioning allows welding access from the exterior while preventing subsequent folding or bending that would cause stress and potential disconnection, thereby maintaining both manufacturing ease and connection reliability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cap structure serves as an intermediary element that receives current collectors extending through it. This intermediary positioning allows the current collectors to be accessible for welding from the exterior while maintaining a stable, stress-free connection that prevents disconnection during operation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If current collectors are connected to terminal leads at the interior side of the battery cap, then connection is established, but clearance requirements increase packaging volume

Engineering Contradiction:

Improveconnection establishmentVSAvoidpackaging volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

Instead of connecting current collectors to terminal leads at the interior side of the cap as in conventional designs, this invention inverts the approach by extending current collectors through the cap to the exterior side for connection. This inversion eliminates the need for interior clearance space, thereby reducing packaging volume while maintaining reliable electrical connection

Inventive Principle:

Principle #13The other way round (Inversion)

3Adaptability or versatility

If current collectors are positioned to allow relative movement during manufacturing, then manufacturing flexibility is improved, but stress and detachment risk increase during operation

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidconnection strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The current collectors are pre-positioned to extend through the cap exterior before final assembly operations. This preliminary positioning establishes a fixed, stress-free connection path that maintains manufacturing flexibility while preventing relative movement that would cause stress and detachment during vehicle operation

Inventive Principle:

Principle #10Preliminary action

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 approach reduces stress on current collectors, enhances connection reliability, and minimizes packaging space, preventing detachment and ensuring stable electrical connections.

Implementation Method 1

The plurality of current collector tabs are electrically connected to respective current collectors of an electrode stack and extend from an end of the electrode stack

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

hermetically sealing the enclosure

Methodology Applied

Scientific EffectHermetic sealing: Physical Containment

Data Source

PatentUS20260051635A1Direct foil to terminal connection designs for prismatic cell manufacturing

Publication Date: 2026.02.19 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method for manufacturing a prismatic battery assembly includes disposing a plurality of current collector tabs at least partially through a slot of a cap of an enclosure. The plurality of current collector tabs are electrically connected to respective current collectors of an electrode stack and extend from an end of the electrode stack. The enclosure accommodates the electrode stack. The cap has an interior side that extends along the end of the electrode stack and an exterior side opposite the interior side. The slot is formed through the cap between the exterior side and the interior side. With the plurality of current collector tabs disposed at least partially through the slot, the method includes electrically connecting the plurality of current collector tabs to a terminal plate disposed at the exterior side of the cap and hermetically sealing the enclosure.