Battery Adapter Sheet Structure to Prevent Tab Welding Cracks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery technologies require auxiliary welding tabs to enhance welding strength, increasing process steps and reducing assembly efficiency, and the direct welding of thin tabs can lead to cracking and safety risks due to bending under stress.
Innovation Solution
An adapter sheet with a main body and support part clamps the tab between them, eliminating the need for auxiliary welding tabs, ensuring welding strength while reducing cracks and providing support to prevent tab bending.
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 part for connecting to the tab, and a support part that provides mechanical support. This integration eliminates the need for separate auxiliary welding tabs, reducing the number of components and assembly steps while maintaining both welding strength and support functionality.
2Device complexity
If direct welding of thin 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 acts as an intermediary component between the thin tab and the external environment. The welding part of the adapter sheet provides a robust welding surface that distributes stress, while the support part provides mechanical reinforcement. This intermediary structure protects the thin tab from direct bending stresses that would cause welding cracks, thereby improving welding reliability without complicating the assembly process.
3Device complexity
If the tab is left unsupported, then the structure is simpler, but the tab bends downward under stress and inserts into the interior of the electrode assembly causing safety issues
Solution Approach 1:
The adapter sheet is segmented into distinct functional parts: a welding part that connects to the tab, a flexible part that allows for movement, and a support part that provides mechanical support. The support part is specifically designed to prevent the tab from bending downward and inserting into the electrode assembly interior. This segmentation allows each part to perform its specific function effectively while maintaining an overall simple 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
This design improves assembly efficiency, reduces welding cracks, enhances welding yield, and increases safety performance by supporting the tab to avoid internal short circuits.
Implementation Method 1
the flexible part is configured to fold the support part relative to the main body
Implementation Method 2
The same-polarity tabs of the cells are first connected to the adapter sheets by ultrasonic welding
Implementation Method 3
the adapter sheets are welded to the corresponding terminals through laser welding
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Disclosed is an adapter sheet (150), configured to electrically connect the electrode assembly (120) and the top cover (172), and including: a main body (10), including a body tab welding part (12) and a body top cover welding part (14) connected to each other; a support part (20) and a flexible part (30), wherein the support part (20) is connected to the main body (10) through the flexible part (30), and the flexible part (30) is configured to fold the support part (20) relative to the main body (10), and a tab (122) of the electrode assembly (120) is clamped between the main body (10) and the support part (20). The purpose of the present disclosure lies in providing an adapter sheet (150), a secondary battery (100), a battery assembly (1002) and an electronic device (1000) to at least improve the safety performance of the secondary battery (100).