Secondary Battery Current Collector Laser Welding
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Solution Overview
Problem
Secondary batteries face challenges in maintaining electrical stability and reducing raw material loss due to the conventional welding process of non-coating portion tabs, which results in increased scrap material and variations in welding quality as the number of stacked tabs increases.
Innovation Solution
The implementation of a laser welding process for a current collector plate to non-coating portion tabs, where the tabs are bent in opposite directions and at least one tab is welded to the plate, reducing tab length and enhancing welding reliability and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding process is used for non-coating portion tabs, then welding can be performed, but welding quality varies as the number of stacked tabs increases and scrap material increases
Solution Approach 1:
The electrode plate is divided into multiple unit electrode plates, each with its own non-coating portion tabs. By segmenting the welding process into individual tab welds rather than attempting to weld all tabs simultaneously, consistent welding quality is achieved regardless of the total number of tabs. The laser welding process treats each tab independently, preventing the quality degradation that occurs with conventional bulk welding methods.
Solution Approach 2:
The conventional mechanical welding process is replaced with laser welding technology. This substitution enables precise, consistent welding of each non-coating portion tab to the current collector plate without the quality variations inherent in mechanical welding. The laser welding process also reduces material waste by providing more precise material removal and joining.
2Loss of substance
If non-coating portion tabs are shortened, then raw material loss is reduced, but welding reliability may be compromised
Solution Approach 1:
Laser welding replaces conventional welding methods, enabling reliable welding of shortened non-coating portion tabs. The precision and control of laser welding allow for successful welding even with reduced tab length, whereas conventional welding would fail to provide consistent reliability with shortened tabs. This substitution resolves the contradiction by maintaining welding reliability while allowing tab length to be optimized for reduced material waste.
3Reliability
If multiple non-coating portion tabs are stacked for welding, then electrical connection is achieved, but welding quality varies and manufacturing complexity increases
Solution Approach 1:
The laser welding process is designed to automatically handle each non-coating portion tab independently without requiring complex manual positioning or adjustment for each tab. The process self-regulates to provide consistent welding quality across all tabs, reducing the manufacturing complexity that would otherwise arise from managing multiple stacked tabs with conventional welding methods.
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 approach reduces raw material loss, maintains consistent welding quality, and increases battery capacity by ensuring stable electrical connections even with increased tab thickness, while also reducing heat generation and improving design flexibility.
Implementation Method 1
The current collector plate may be laser welded to the non-coating portion tabs
Data Source
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AI summary
A secondary battery having an improved current-collecting structure is provided. In an example embodiment, the secondary battery includes an electrode assembly (100a) including a plurality of unit electrode plates (100) each including a pair of non-coating portion tabs (140) at a side and a plurality of separators each located between the unit electrode plates (140); and the pair of non-coating portion tabs (140) are bent in opposite directions and welded to a current collector plate (300). The pair of non-coating portion tabs are bent in opposite directions to be welded to the current collector plate, and welding may be complementarily performed, thereby securing electrical stability.