Nonwoven fabric composite current collector tab welding structure
By using a non-woven composite current collector electrode tab welding structure, electrical conduction is achieved by using metal protrusions to penetrate the electrode tab, which solves the problem of low welding efficiency in the existing technology and realizes a high-efficiency and stable connection between the electrode tab and the soft connecting piece.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANDONG ASROCK CONDUCTIVE NEW MATERIALS TECHNOLOGY CO LTD
- Filing Date
- 2025-08-29
- Publication Date
- 2026-07-24
AI Technical Summary
When welding existing composite current collector tabs, the insulation layer blocks ultrasonic energy, making direct welding impossible. This requires the introduction of additional metal foil, increasing material costs, processing time, and the risk of incomplete welds, resulting in low production efficiency and high costs.
A non-woven composite current collector electrode tab welding structure is adopted. The metal protrusions on the plate penetrate the two metal layers of the electrode tab to achieve electrical conduction and are welded to the flexible connecting piece, replacing the two metal foils required in the traditional process, simplifying the structure and welding steps.
It reduces material consumption and manufacturing costs, simplifies structural hierarchy, improves welding efficiency and connection stability between electrode tabs and flexible connecting pieces, reduces the risk of solder joint detachment, and optimizes current conduction uniformity and connection strength.
Smart Images
Figure CN224554644U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of composite current collector technology, specifically to a non-woven composite current collector electrode tab welding structure. Background Technology
[0002] As new energy lithium batteries develop towards higher energy density, higher safety, and lower cost, composite current collectors, due to their advantages of being lightweight, highly corrosion-resistant, and having low material costs, are gradually replacing traditional pure metal current collectors (such as copper foil and aluminum foil) and are widely used in power lithium batteries, energy storage batteries, and other fields.
[0003] Most existing composite current collectors are composed of a sandwich structure of "metal layer-insulation layer-metal layer". The insulation layer is often made of polymer materials such as PP (polypropylene), PET (polyethylene terephthalate) or non-woven fabric, while the metal layers on both sides are conductive metals such as copper and aluminum (the thickness is usually 1-5μm).
[0004] When composite current collectors are stacked and welded, each composite current collector tab of the same polarity needs to be welded together using a flexible connecting piece as a medium to achieve electrical conductivity.
[0005] When welding existing composite current collector tabs to flexible connectors, the non-conductive insulation layer prevents direct current flow between the metal layers on both sides of the tab. This results in the absorption or blockage of ultrasonic energy by the insulation layer, hindering the direct welding of the tab to the flexible connector through heat generation via metal atomic vibration and friction. To address this issue, the industry commonly employs a "copper foil transfer welding process." This process involves first welding two metal foils to the metal layers on both sides of the tab, then performing a secondary welding of these foils to the flexible connector. This indirectly achieves electrical connection between the metal layers on both sides of the tab and the flexible connector through the metal foils.
[0006] However, because stacked welding requires multiple layers of composite current collectors, each electrode tab requires the introduction of two additional metal foils and two welding operations. For battery packs that need to stack multiple current collectors, material costs, processing time, and structural complexity (due to the increased number of layers) all increase significantly. At the same time, the increased number of solder joints also introduces more potential failure risks such as incomplete soldering and detachment, ultimately leading to problems such as low production efficiency and high manufacturing costs. Utility Model Content
[0007] In view of this, the present invention provides a non-woven composite current collector electrode tab welding structure, which eliminates the need for additional metal foil welding of a single composite current collector electrode tab. This reduces manufacturing costs, decreases the number of stacked layers in the electrode tab welding area, directly reduces the number of welding operations between materials, significantly improves welding efficiency, greatly reduces the risk of weld point detachment, and further enhances the long-term stability of the connection between the electrode tab and the flexible connecting piece.
[0008] To solve the above-mentioned technical problems, this utility model provides a non-woven composite current collector electrode tab welding structure, including an electrode tab composed of two metal layers and an insulating layer sandwiched between the two metal layers. It also includes a plate-like object covering and adhering to the surface of one of the metal layers of the electrode tab. At least one metal protrusion is provided on the plane of the plate-like object facing the metal layer. When it is necessary to weld and fix the flexible connecting piece and the electrode tab, the plate-like object is adhered to one of the metal layers, and then pressure is applied to force the protrusion to penetrate the two metal layers and the intermediate insulating layer of the electrode tab, so that the two metal layers can achieve electrical conductivity through the penetrating protrusion. Finally, the end of the protrusion extending after penetrating the electrode tab is welded and fixed to the flexible connecting piece, thus ensuring the connection between the flexible connecting piece and the electrode tab. On the other side, the metal layers are tightly bonded. After welding, the raised strip will achieve electrical conductivity with the flexible connecting piece, thus forming a complete conductive path between the two metal layers of the tab, the raised strip, and the flexible connecting piece, thereby completing the welding operation between the tab and the flexible connecting piece. Through the penetrating setting of the raised strip, a single plate can directly replace the two metal foils required in the existing process. Only one flexible connecting piece needs to be welded to achieve conductivity. This not only reduces the amount of metal foil used and lowers manufacturing costs, but also reduces the number of stacked layers in the tab welding area, significantly improving welding efficiency. At the same time, the number of weld points is reduced from multiple sets in the traditional process to one set of the raised strip and flexible connecting piece, greatly reducing the risk of weld point detachment and further improving the long-term stability of the connection between the tab and the flexible connecting piece.
[0009] The tab forms a welding area where it is in contact with the flexible connecting piece. When the plate is attached to the tab, it can cover the welding area, so that the plate can not only serve as a base for the protrusion but also as a protective plate for the tab, thus protecting the tab and preventing it from wrinkling or tearing.
[0010] The convex strip and the plate are integrally molded structures, so both the convex strip and the plate are made of the same metal material, which improves the connection strength between the convex strip and the plate and enhances stability.
[0011] The end of the protrusion used to penetrate the electrode tab has a piercing part, which makes it easier for the protrusion to penetrate the electrode tab.
[0012] The puncture site has a conical structure. This conical structure reduces the contact area between the end of the protrusion and the metal and insulating layers, concentrating the pressure applied by the plate-like object at the tip of the conical structure and reducing penetration resistance.
[0013] The number of protrusions is multiple, and these protrusions can be arranged in a linear array or a ring array on the surface of the plate. The design of multiple protrusions allows the current to be dispersed and conducted through the protrusions, improving the uniformity of conduction.
[0014] The protrusion is a columnar structure with a circular cross-section. Its tip can make the mechanical strength of the protrusion more uniform in all directions during the penetration process. Multiple protrusions are distributed at equal intervals along the length and width of the plate, so that the distance between each two adjacent protrusions is equal, ensuring that the current is evenly distributed on the surface of the electrode.
[0015] The raised strip is a long strip structure with a rectangular cross-section. After penetrating the metal layer, this long strip can increase the contact length and area between the individual raised strip and the metal layer, thereby improving the current conduction effect. Furthermore, multiple raised strips are evenly distributed along the length of the plate, which improves the uniformity of current conduction.
[0016] Multiple convex strips are arranged in at least two parallel rows along the length of the plate. The multiple rows of parallel convex strips can increase the conductive area in the width direction of the tab, so that the current is evenly conducted in the width direction of the tab. At the same time, the multiple rows of structures enhance the connection strength between the tab and the flexible connecting piece.
[0017] The adjacent rows of convex strips are staggered in the width direction of the plate. The staggered distribution can reduce the projected gap of the convex strips in the width direction of the electrode, avoiding the problem of weak current in the gap area that may occur when they are parallel. At the same time, the staggered structure makes the stress points of the electrode more dispersed, reducing local stress concentration.
[0018] In summary, compared with the prior art, this application includes at least one of the following beneficial technical effects:
[0019] 1. Reduce material consumption and simplify structural hierarchy. By replacing the two metal foils required in the traditional process with metal protrusions on the plate, electrical conduction between the two metal layers of the tab can be achieved without the need to introduce additional metal foil, which reduces manufacturing costs and avoids the redundancy of stacked layers in the tab welding area caused by metal foil, making the overall structure simpler and more compact.
[0020] 2. Reduce welding steps and improve production efficiency. Only one welding is required after the protrusion passes through the tab and is welded to the flexible connecting piece. This simultaneously achieves the connection between the two metal layers and fixes the tab and flexible connecting piece, eliminating the welding steps between the metal foil and the tab, reducing the number of welding operations between materials, and significantly improving welding efficiency.
[0021] 3. Protect the tab structure and reduce the probability of damage. When the plate is attached to the tab, it can cover the welding area between the tab and the flexible connecting piece. It not only serves as the mounting base for the protrusion, but also acts as a protective structure for the tab. During welding pressure and subsequent use, it effectively prevents the tab from being damaged by uneven force, such as wrinkles and tears, and ensures the structural integrity of the tab.
[0022] 4. Scientifically distributed convex strips optimize current conduction and connection reliability. The convex strips can be arranged in an array, multiple rows of parallel strips, or staggered distribution to avoid local problems caused by current concentration in a single convex strip. This allows the current to be conducted evenly in both length and width directions. The staggered distribution can eliminate weak current areas caused by gaps between convex strips, while also dispersing the stress points of the electrode tabs and reducing local stress concentration. This not only improves the uniformity of current conduction but also enhances the connection strength between the electrode tabs and the flexible connecting piece. Attached Figure Description
[0023] Figure 1 This is a schematic diagram of the structure of the electrode tab and flexible connecting piece after welding of this utility model;
[0024] Figure 2 This is a schematic diagram of the plate-like structure in Embodiment 1 of this utility model;
[0025] Figure 3 This is a schematic diagram of the plate-like structure in Embodiment 2 of this utility model;
[0026] Figure 4 This is a schematic diagram of the plate-like structure in Embodiment 3 of this utility model.
[0027] Explanation of reference numerals in the attached figures:
[0028] 100. Plate-like object; 101. Raised strip; 102. Puncture section; 200. Flexible connecting piece; 300. Insulating layer; 301. Metal layer. Detailed Implementation
[0029] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the following will be described in conjunction with the accompanying drawings of the embodiments of this utility model. Figure 1-4 The technical solutions of the embodiments of this utility model are clearly and completely described herein. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the described embodiments of this utility model are within the protection scope of this utility model.
[0030] Example 1:
[0031] A nonwoven composite current collector tab welding structure, such as Figure 1 and Figure 2 As shown: It includes a tab, which is composed of two metal layers 301 and an insulating layer 300 sandwiched between the two metal layers 301. It also includes a plate 100, which covers and adheres to the surface of one of the metal layers 301 of the tab. The plate 100 has at least one metal protrusion 101 on a plane facing the metal layer 301.
[0032] When it is necessary to weld and fix the flexible connector 200 and the electrode, the plate 100 is attached to one of the metal layers 301. Then, by applying pressure, the protrusion 101 penetrates the two metal layers 301 and the intermediate insulating layer 300 of the electrode. Since the protrusion 101 is made of metal, after the protrusion 101 penetrates the two metal layers 301, the two metal layers 301 will use the protrusion 101 as a conductive medium so that the two metal layers 301 can achieve electrical conduction through the penetrating protrusion 101.
[0033] Finally, the end of the protrusion 101 that extends through the tab is welded to the flexible connecting piece 200 and the metal layer 301 on the other side of the tab is tightly bonded. The welding method can be ultrasonic vibration welding or traditional heating welding.
[0034] After welding, the protrusion 101 will achieve electrical conductivity with the flexible connecting piece 200, thereby forming a complete conductive path between the two metal layers 301 of the electrode tab, the protrusion 101, and the flexible connecting piece 200, thus completing the welding operation between the electrode tab and the flexible connecting piece 200. Through the penetration setting of the protrusion 101, a plate-shaped object 100 can directly replace the two metal foils required in the existing process, so that a single composite current collector electrode tab does not need to be additionally welded with metal foil, but only needs to be welded with a flexible connecting piece 200 to achieve conductivity. While reducing manufacturing costs, it also reduces the number of stacked layers in the electrode tab welding area. Moreover, since the two welding steps between the metal foil and the electrode tab are eliminated, the number of welding steps between materials is directly reduced, significantly improving welding efficiency. At the same time, the number of welding points is reduced from multiple sets in the traditional process to one set of the protrusion 101 and the flexible connecting piece 200, greatly reducing the risk of welding point detachment and further improving the long-term stability of the connection between the electrode tab and the flexible connecting piece 200.
[0035] Specifically, the tab forms a welding area in the part that is in contact with the flexible connecting piece 200, and the area of the plate 100 that is in contact with the metal layer 301 in the tab is larger than the area of the welding area. Therefore, when the plate 100 is attached to the tab, the plate 100 can cover the welding area, so that the plate 100 can not only serve as a base for the protrusion 101, but also as a protective sheet for the tab, so that the protective sheet of the plate 100 can protect the tab and prevent the tab from wrinkling or tearing.
[0036] Specifically, the protrusion 101 and the plate 100 are integrally formed structures, so the protrusion 101 and the plate 100 are made of the same metal material, which improves the connection strength between the protrusion 101 and the plate 100 and enhances stability.
[0037] Specifically, the end of the protrusion 101 used to penetrate the electrode tab is provided with a piercing part 102, which makes it easier for the protrusion 101 to penetrate the electrode tab.
[0038] Specifically, the puncture section 102 has a conical structure. The conical structure reduces the contact area between the end of the protrusion 101 and the metal layer 301 and the insulating layer 300, and concentrates the pressure applied by the plate 100 at the tip of the conical structure to form a local high pressure, reduce the penetration resistance, and reduce the risk of electrode deformation.
[0039] Specifically, there are multiple protrusions 101. These protrusions 101 can be arranged in a linear array or a ring array on the surface of the plate 100. The design of multiple protrusions 101 allows current to be dispersed and conducted through the protrusions 101, improving the uniformity of conduction and avoiding localized heating of a single protrusion 101.
[0040] Furthermore, the protrusion 101 is a columnar structure with a circular cross-section. Its tip can make the mechanical strength of the protrusion 101 more uniform in all directions during the penetration process. The multiple protrusions 101 are distributed at equal intervals along the length and width directions of the plate 100, so that the distance between each two adjacent protrusions 101 is equal, ensuring that the current is evenly distributed on the surface of the electrode and avoiding excessively high local current density.
[0041] Example 2:
[0042] The difference from Example 1 is as follows:
[0043] according to Figure 3 As shown, the protrusion 101 is a long strip structure with a rectangular cross-section. After penetrating the metal layer 301, this long strip protrusion 101 can increase the contact length and area between a single protrusion 101 and the metal layer 301, thereby improving the current conduction effect.
[0044] Furthermore, multiple protrusions 101 are evenly distributed along the length of the plate 100 to improve the uniformity of current conduction.
[0045] Example 3:
[0046] The difference from Example 2 is as follows:
[0047] according to Figure 4 As shown, multiple protrusions 101 are arranged in at least two parallel rows along the length of the plate 100. The multiple rows of parallel protrusions 101 can increase the conductive area in the width direction of the tab, so that the current is evenly conducted in the width direction of the tab. At the same time, the multiple rows of structures enhance the connection strength between the tab and the flexible connecting piece 200.
[0048] Furthermore, the adjacent rows of protrusions 101 are staggered in the width direction of the plate 100. The staggered distribution can reduce the projected gap of the protrusions 101 in the width direction of the tab, avoiding the problem of weak current in the gap area that may occur when they are parallel. At the same time, the staggered structure makes the stress points of the tab more dispersed, reducing local stress concentration.
[0049] It should be clarified that this utility model relates to the welding and conductive flow of composite current collector tabs. It is important to note that both the tabs and the flexible connecting piece 200 of the composite current collector are existing technologies. The composite current collector consists of two metal layers 301 and an intermediate insulating layer 300. Since this is not an innovation of this utility model, no specific model is specified, nor is its structure described in detail. Only the usage and installation position of the plate-shaped object 100 and the raised strip 101 are described in detail. The above description represents the preferred embodiment of this utility model. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles described in this utility model, and these improvements and modifications should also be considered within the scope of protection of this utility model.
Claims
1. A nonwoven composite current collector electrode tab welding structure, comprising an electrode tab, the electrode tab comprising two metal layers (301) and an insulating layer (300) between the two metal layers (301), characterized in that: Includes a plate-shaped object (100), on one of its planes at least one metal protrusion (101); The plate (100) is attached to one of the metal layers (301), and the protrusion (101) can penetrate both metal layers (301) and the insulating layer (300) so that the two metal layers (301) can be electrically connected through the penetrating protrusion (101); The end of the protrusion (101) that passes through the tab is welded and fixed to the flexible connecting piece (200) to form an electrical connection path between the tab and the flexible connecting piece (200).
2. The nonwoven composite current collector tab welding structure as described in claim 1, characterized in that: The projection of the plate (100) on the surface of the tab covers the area where the tab and the flexible connecting piece (200) are in contact.
3. The nonwoven composite current collector tab welding structure as described in claim 1, characterized in that: The protruding strip (101) and the plate (100) are integrally formed structures.
4. The nonwoven composite current collector tab welding structure as described in claim 1, characterized in that: The end of the protrusion (101) that is used to penetrate the electrode ear is provided with a piercing part (102).
5. The nonwoven composite current collector tab welding structure as described in claim 4, characterized in that: The puncture section (102) has a conical structure.
6. The nonwoven composite current collector tab welding structure as described in claim 3, characterized in that: The number of the protrusions (101) is multiple, and the multiple protrusions (101) are distributed in an array on the surface of the plate (100).
7. The nonwoven composite current collector tab welding structure as described in claim 6, characterized in that: The protrusion (101) is a columnar structure with a circular cross-section; Furthermore, the plurality of the protrusions (101) are distributed at equal intervals along the length and width directions of the plate (100).
8. The nonwoven composite current collector tab welding structure as described in claim 6, characterized in that: The protruding strip (101) is a strip-shaped structure with a rectangular cross-section; Furthermore, the plurality of the protrusions (101) are distributed at equal intervals along the length direction of the plate (100).
9. The nonwoven composite current collector tab welding structure as described in claim 8, characterized in that: The plurality of the protrusions (101) are arranged in at least two parallel rows along the length of the plate (100).
10. The nonwoven composite current collector tab welding structure as described in claim 9, characterized in that: The protrusions (101) in two adjacent rows are staggered in the width direction of the plate (100).