Ultrasonic Welding of Battery Electrode Assembly
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Solution Overview
Problem
Conductive foreign substances such as metal pieces or powder can intrude into the electrode assembly of energy storage devices, leading to defects like short-circuiting, which existing manufacturing methods and usage factors fail to adequately prevent.
Innovation Solution
The energy storage device design includes an electrode assembly with electrode plates stacked and welded at specific end portions, and a current collector joined to these portions using ultrasonic welding, reducing gaps and ensuring reliable connection while preventing foreign substance intrusion through strategically arranged electrode plate welded and current collector joined portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding is performed to join electrode plates and current collector, then joining strength is improved, but metal powder is generated and may intrude into the electrode assembly causing short-circuiting
Solution Approach 1:
The patent extracts and removes the harmful metal powder generated during ultrasonic welding from the welding zone before it can intrude into the electrode assembly. A blowing device introduces gas to blow the metal powder away from the electrode assembly, effectively separating the harmful byproduct from the useful joining process.
Solution Approach 2:
The patent introduces gas as an intermediary substance between the ultrasonic welding process and the electrode assembly. This gas medium carries the metal powder away from the welding zone, preventing direct contact and intrusion into the electrode assembly while allowing the welding process to continue.
2Stability of the object's composition
If electrode plates are welded to each other in stacking direction, then structural integrity is improved, but gaps may remain at end portions allowing foreign substance intrusion
Solution Approach 1:
The patent applies preliminary action by forming protrusions on the electrode plates before welding. These protrusions are created at the end portions of the electrode plates to prevent gaps from forming during the welding process, thereby preventing foreign substance intrusion before it can occur.
Solution Approach 2:
The patent applies local quality by creating protrusions only at the end portions of the electrode plates where gaps are most likely to form. This localized modification ensures that the welding process maintains structural integrity while specifically addressing the vulnerability at the end portions to foreign substance intrusion.
3Reliability
If current collector is joined to electrode assembly, then electrical connection is improved, but complexity of manufacturing process increases
Solution Approach 1:
The patent merges the joining of the current collector to the electrode assembly with the ultrasonic welding process used for joining electrode plates. By using the same ultrasonic welding technology for both operations, the manufacturing process complexity is reduced while maintaining reliable electrical connection.
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 configuration enhances the reliability of energy storage devices by reducing the likelihood of foreign substance intrusion and ensuring high-quality joining, thereby minimizing defects like short-circuiting and maintaining power generation efficiency.
Implementation Method 1
a current collector joined portion which is joined to the current collector and is arranged adjacently to the electrode plate welded portion
Data Source
AI summary
Provided is an energy storage device which includes an electrode assembly in which electrode plates are stacked; and a current collector connected to an end portion of the electrode assembly, wherein the end portion of the electrode assembly includes: an electrode plate welded portion at which the stacked electrode plates are welded to each other in a stacking direction and not joined to the current collector; and a current collector joined portion which is joined to the current collector and is arranged adjacently to the electrode plate welded portion in a current collector extending direction that intersects with the stacking direction.