Battery Adapter Sheet With Folded Tab Clamp for Crack-Resistant Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery technologies require auxiliary welding tabs to enhance welding strength, which increases process steps and reduces assembly efficiency, and the direct welding of thin copper tabs is prone to cracking and safety risks due to bending under stress.
Innovation Solution
An adapter sheet with a main body and support part that clamps the tab, eliminating the need for auxiliary welding tabs, ensuring welding strength and reducing cracks, while providing support to prevent tab bending during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If auxiliary welding tabs are used to enhance welding strength, then welding strength is improved, but process steps increase and assembly efficiency decreases
Solution Approach 1:
The patent combines the welding tab function and the support function into a single integrated adapter sheet structure. The adapter sheet includes a main body with a welding tab welding part and a support part that is folded and clamped between the main body and the electrode assembly tab. This integration eliminates the need for separate auxiliary welding tabs, thereby reducing process steps while maintaining welding strength through the clamping action of the support part.
2Device complexity
If direct welding of thin copper tabs is performed, then assembly process is simplified, but welding cracks occur and safety risks increase due to bending under stress
Solution Approach 1:
The adapter sheet is segmented into functional parts: a main body with welding tab welding part for electrical connection, and a separate support part that is folded and clamped to provide mechanical support. This segmentation allows the thin copper tab to be welded directly without auxiliary tabs while the support part prevents bending and cracking by providing structural reinforcement through the clamping action.
3Device complexity
If the tab is left unsupported during assembly, then the structure is simpler, but the tab bends downward under stress and inserts into the electrode assembly causing safety issues
Solution Approach 1:
The support part of the adapter sheet is designed to be folded, creating a dynamic structure that can be positioned to clamp the tab. The flexible part allows the support part to be folded relative to the main body, enabling the clamping action that prevents tab bending downward during assembly while maintaining a relatively simple overall structure.
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
Improves assembly efficiency, reduces welding cracks, and enhances safety performance by maintaining welding strength and preventing tab insertion into the electrode assembly, thus improving yield and high potential test results.
Implementation Method 1
a flexible part, the support part is connected to the main body through the flexible part, and the flexible part is configured to fold the support part relative to the main body
Implementation Method 2
a tab of the electrode assembly is clamped between the main body and the support part
Implementation Method 3
The same-polarity tabs of the cells are first connected to the adapter sheets by ultrasonic welding
Implementation Method 4
then the adapter sheets are welded to the corresponding terminals through laser welding
Data Source
AI summary
Disclosed is an adapter sheet, configured to electrically connect the electrode assembly and the top cover, and including: a main body, including a body tab welding part and a body top cover welding part connected to each other; a support part and a flexible part, wherein the support part is connected to the main body through the flexible part, and the flexible part is configured to fold the support part relative to the main body, and a tab of the electrode assembly is clamped between the main body and the support part. The purpose of the present disclosure lies in providing an adapter sheet, a secondary battery, a battery assembly and an electronic device to at least improve the safety performance of the secondary battery.