Secondary Battery Electrode Assembly Ultrasonic Welding Support
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Solution Overview
Problem
Secondary batteries face limitations in capacity and manufacturing efficiency due to the constraints of existing designs, particularly in the arrangement and welding of electrode assemblies within a single case.
Innovation Solution
The solution involves using at least two electrode assemblies in a single case with non-coating portions on collecting plates that are spaced apart from the roll centers of the electrode assemblies, allowing for increased capacity and efficient ultrasonic welding by inserting an ultrasonic welding support between the collecting plates, which minimizes damage and reduces manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple electrode assemblies are arranged in a single case to increase capacity, then the battery capacity increases, but the manufacturing complexity and welding difficulty increase
Solution Approach 1:
The battery is divided into multiple electrode assemblies (first electrode assembly and second electrode assembly), each with its own collecting plates and non-coating portions. This segmentation allows independent handling and welding of each assembly, reducing overall manufacturing complexity while maintaining increased capacity
Solution Approach 2:
An ultrasonic welding support is introduced as an intermediary component between the collecting plates during the welding process. This support facilitates easier welding operations and reduces manufacturing difficulty by providing a stable platform for the welding process
2Volume of moving object
If collecting plates are positioned close to roll centers for compact design, then the battery volume efficiency improves, but the welding process becomes difficult and time-consuming
Solution Approach 1:
The ultrasonic welding support acts as a mediator that enables efficient welding even when collecting plates are positioned for optimal volume efficiency. The support provides access and stability for the welding process without requiring the collecting plates to be repositioned, thus maintaining both volume efficiency and welding productivity
Solution Approach 2:
The non-coating portions are pre-positioned at specific distances from the roll centers, and the ultrasonic welding support is pre-configured to match these positions. This preliminary arrangement ensures that welding can proceed efficiently without requiring additional adjustments during the welding process
3Ease of manufacture
If traditional welding methods are used for collecting plates, then manufacturing costs are high and production time is long, but the collecting plates may be damaged
Solution Approach 1:
Traditional mechanical welding methods are replaced with ultrasonic welding, which uses high-frequency vibration to join the collecting plates to the non-coating portions. This substitution reduces manufacturing time and costs while minimizing damage to the collecting plates, as ultrasonic welding applies less mechanical stress and heat compared to traditional welding methods
Solution Approach 2:
The ultrasonic welding support serves as a mediator that protects the collecting plates from direct contact with welding tools, preventing damage while enabling efficient welding. The support distributes the welding forces and provides a stable platform that reduces the risk of collecting plate deformation or damage
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 capacity of the secondary battery and simplifies the manufacturing process by allowing easier insertion and welding of the ultrasonic welding support, thereby reducing production time and costs while preventing damage to the collecting plates.
Implementation Method 1
efficient ultrasonic welding by inserting an ultrasonic welding support between the collecting plates
Data Source
AI summary
A secondary battery includes first and second collecting plates branching out from an electrode terminal, and first and second electrode assemblies rolled up in a jelly-roll type unit, the first electrode assembly having a first non-coating portion adhered to the first collecting plate, the second electrode assembly having a second non-coating portion adhered to the second collecting plate, and the first and second collecting plates being on facing surfaces of respective first and second non-coating portions. The first non-coating portion is spaced apart from a roll center of the first electrode assembly by a first predetermined distance along a direction directed away from the second non-coating portion, and the second non-coating portion is spaced apart from a roll center of the second electrode assembly by a second predetermined distance along a direction directed away from the first non-coating portion.