Squeeze Pin Connects Battery Electrode Tab to Lead Terminal
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Solution Overview
Problem
Existing methods for connecting electrode tabs to lead terminals in lithium secondary batteries, such as ultrasonic welding, resistance welding, and laser welding, are costly, unreliable, and prone to damaging the protection circuit module, especially when using aluminum materials.
Innovation Solution
The use of a squeeze pin to physically and electrically connect the lead terminals to the electrode tabs, which forms a space to stack the terminals and uses a pressurizing part to ensure a secure connection without direct welding, allowing for improved coupling intensity and reduced material-specific welding requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to connect lead terminal to electrode tab, then electrical connection is achieved, but protection circuit module is damaged by ultrasonic vibrations
Solution Approach 1:
The connection structure is divided into separate components: the lead terminal, the electrode tab, and the squeeze pin. The squeeze pin acts as an independent mechanical fastener that separates the mechanical connection function from the electrical connection function, eliminating the need for ultrasonic welding and thus preventing vibration damage to the protection circuit module.
Solution Approach 2:
The squeeze pin serves as an intermediary component between the lead terminal and the electrode tab. It provides mechanical pressure to ensure electrical contact without generating harmful vibrations, thus mediating the connection in a way that protects the protection circuit module while maintaining electrical connectivity.
2Reliability
If laser welding equipment is used to connect lead terminal to electrode tab, then strong electrical connection is achieved, but equipment cost and maintenance cost increase significantly
Solution Approach 1:
The patent replaces the laser welding system (optical/thermal field) with a simple mechanical compression system using the squeeze pin. This mechanical approach achieves sufficient electrical connection through pressure-induced contact without requiring expensive laser equipment, thereby reducing both initial investment and maintenance costs while maintaining connection reliability.
Solution Approach 2:
The squeeze pin is a simple, inexpensive mechanical component that can be easily replaced if needed, unlike expensive laser welding equipment. This approach uses a low-cost component to achieve the connection function, significantly reducing manufacturing equipment investment and ongoing maintenance expenses.
3Reliability
If resistance welding is used to connect lead terminal to electrode tab, then electrical connection is achieved, but application range is limited and aluminum materials cannot be processed
Solution Approach 1:
The squeeze pin design provides a universal connection method that works with various materials including aluminum, copper, and other conductive materials. Unlike resistance welding which is material-specific, the mechanical compression approach is universally applicable to different electrode tab and lead terminal material combinations, significantly expanding the adaptability of the connection system.
4Reliability
If welding methods are used to connect lead terminal to electrode tab, then electrical connection is achieved, but coupling intensity between tab and terminal is insufficient
Solution Approach 1:
The squeeze pin is pre-designed with a specific structure that includes a pressing portion and a positioning portion. The positioning portion is inserted into the lead terminal first, then the pressing portion applies compression force to the electrode tab, ensuring proper alignment and maximum contact pressure before the connection is finalized. This preliminary positioning action ensures optimal coupling intensity from the start.
Solution Approach 2:
The pressing portion of the squeeze pin has a curved surface that contacts the electrode tab. This curved surface distributes the compression force evenly across the contact area, increasing the effective coupling intensity between the lead terminal and electrode tab compared to flat or pointed contact surfaces.
Data Source
AI summary
A squeeze pin and a secondary battery using the same improve the coupling intensity of an electrode tab and a lead terminal, prevent damage of a protection circuit module, and reduce the cost. The secondary battery includes an outer case; an electrode assembly accommodated in the outer case and including a positive electrode plate connected to a positive electrode tab, a negative electrode plate connected to a negative electrode tab, and a separator; a protective circuit board including first and second connection terminals; and a first lead terminal connecting the positive electrode tab to the first connection terminal and a second lead terminal connecting the negative electrode tab to the second connection terminal, wherein at least one of the first lead terminal and the positive electrode tab, or the second lead terminal and the negative electrode tab are physically electrically connected to each other.