Rivet Coupling for Secondary Battery Terminals
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Solution Overview
Problem
Existing secondary battery manufacturing methods face challenges in securely and cost-effectively coupling electrode terminals to terminal plates, particularly due to differences in thermal expansion coefficients between materials, which can lead to decoupling under temperature changes and increased manufacturing costs from welding processes.
Innovation Solution
The use of a rivet pin system where the rivet pin is pressingly inserted into a tapered rivet groove on the electrode terminal, coupling it to a terminal plate with a different material, thereby stabilizing the connection without direct welding, simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to couple electrode terminals to terminal plates, then connection strength is improved, but manufacturing cost increases and thermal expansion differences cause decoupling
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical riveting system. The rivet pin is inserted through the electrode terminal and terminal plate, then deformed to create a mechanical interlock that provides secure coupling without the high costs and thermal expansion issues of welding.
Solution Approach 2:
The rivet pin serves as an intermediary component between the electrode terminal and terminal plate. This intermediate element facilitates the connection by absorbing mechanical stresses and accommodating thermal expansion differences, preventing direct stress transmission that would cause decoupling in welded joints.
2Strength
If welding is used to couple electrode terminals to terminal plates, then connection strength is improved, but reliability decreases due to decoupling under temperature changes
Solution Approach 1:
The patent changes the coupling mechanism from thermal/chemical (welding) to mechanical (riveting). The rivet pin's mechanical deformation creates a flexible connection that can accommodate thermal expansion and contraction, maintaining reliable coupling across temperature variations where welded joints would fail.
Solution Approach 2:
The rivet pin acts as a mediator that absorbs thermal stresses. Its mechanical interlock design allows for controlled movement and deformation, preventing the stress transmission that causes welded joints to decouple under temperature changes.
3Device complexity
If direct welding is used to couple electrode terminals to terminal plates, then manufacturing process is simplified, but manufacturing cost increases
Solution Approach 1:
The patent substitutes the expensive welding process with a mechanical riveting system. While the riveting process has multiple steps (insertion, deformation, securing), it eliminates the high equipment costs, material costs, and quality control expenses associated with welding, resulting in lower overall manufacturing costs.
Solution Approach 2:
The coupling process is segmented into distinct operations: inserting the rivet pin, deforming it to create the interlock, and securing the connection. This segmentation allows for simpler, more cost-effective equipment and process control compared to the monolithic welding operation.
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 method provides a stable and secure coupling of electrode terminals to terminal plates, reducing manufacturing costs and maintaining the connection even under temperature changes, while avoiding the need for direct welding.
Implementation Method 1
the rivet pin may have a tapered shape that narrows along a protruding direction thereof, the rivet pin being larger than the rivet groove such that the electrode terminal is deformed when the rivet pin is pressingly inserted into the rivet groove
Data Source
AI summary
A secondary battery and a method for manufacturing a secondary battery, the battery including a case having an internal space; an electrode assembly in the case, the electrode assembly including a first electrode plate, a second electrode plate, and a separator; a cap plate coupled with the case and sealing the case; and an electrode terminal part passing through the cap plate, the electrode terminal part including electrode terminals and a terminal plate, wherein the electrode terminal and the terminal plate are made of different materials are coupled to each other by riveting.