Battery Coupling Frame for Tab-to-Lead Mechanical Interlock
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Solution Overview
Problem
Conventional welding methods for mechanically coupling electrode tabs and leads in batteries can result in uneven surfaces, potentially causing electrical short circuits and damage to the pouch case, which insulating tapes cannot completely prevent.
Innovation Solution
A coupling frame with needle-type perforating portions and a support body that penetrates the contact surface between the electrode tab and lead, optionally including a pipe part with a thermally conductive and electrically conductive material and a filler that becomes fluid with heat, enhancing mechanical coupling and preventing damage to the battery exterior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to mechanically couple the electrode tab and electrode lead, then bonding strength is improved, but the surface becomes uneven causing potential electrical short circuits and damage to the pouch case
Solution Approach 1:
The patent introduces a coupling frame as an intermediary component between the electrode tab and electrode lead. This frame provides a smooth coupling surface that prevents electrical short circuits while maintaining strong mechanical bonding, thus resolving the contradiction between bonding strength and electrical safety
Solution Approach 2:
The patent replaces the welding process with a mechanical coupling system using a coupling frame. This substitution eliminates the uneven surface and potential electrical short circuits caused by welding, while achieving adequate bonding strength through mechanical interlocking and adhesive bonding
2Reliability
If insulating tape is applied to cover the welded portion, then electrical short circuit risk is reduced, but the pouch case damage cannot be completely prevented due to limited tape thickness
Solution Approach 1:
The coupling frame serves as a substantial intermediary structure that provides both electrical insulation and mechanical protection. Unlike thin insulating tape, the frame's sufficient thickness prevents pouch case damage while maintaining electrical insulation, thus resolving the contradiction between electrical safety and physical protection
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
The coupling frame provides robust mechanical coupling between the electrode tab and lead, preventing damage to the battery exterior and reducing the risk of electrical short circuits, while allowing for increased coupling strength compared to traditional welding methods.
Implementation Method 1
a first perforating portion bent from one end of the support body to have a first angle with the support body and having a needle-type tip... The first perforating portion is inserted into the electrode tab and the electrode lead to pass through a first point of a contact surface
Implementation Method 2
a pipe part connected to the support body and having an inner space, so that at least one hole connected to the inner space is formed therein; and a filler accommodated in the inner space and having fluidity when a predetermined condition is satisfied
Implementation Method 3
the pipe part may include a material with thermal conductivity and electric conductivity, and the filler may include a thermosetting material
Data Source
AI summary
A coupling frame includes a support body configured to contact at least one of the electrode tab and the electrode lead; a first perforating portion bent from one end of the support body; and a second perforating portion bent from the other end of the support body. The first and second perforating portions are inserted into the electrode tab and the electrode lead to pass through first and second points of a contact surface between the electrode tab and the electrode lead.