Secondary Battery Lead Member Segmentation for Ultrasonic Welding
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Solution Overview
Problem
Secondary batteries face challenges in achieving strong bond strength between electrode tabs and lead members, leading to increased electrical resistance and reduced charging and discharging efficiencies.
Innovation Solution
The implementation of a secondary battery design with a lead member having separate parts and an insulating member, where the electrode tabs are ultrasonically welded to the lead member, reducing electrical resistance and enhancing bonding strength by localizing vibration energy and preventing physical interference during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional lead member structure is used, then the device complexity is low, but the bond strength between electrode tabs and lead member is insufficient
Solution Approach 1:
The lead member is divided into multiple separate parts (first lead member and second lead member) instead of using a single continuous structure. This segmentation allows each part to be independently positioned and welded to the electrode tabs, improving bond strength while the modular design actually simplifies the welding process by allowing sequential operation.
2Reliability
If electrode tabs are welded to lead member, then electrical connection is established, but electrical resistance increases due to poor bond strength
Solution Approach 1:
By dividing the lead member into separate parts, each part can be optimally positioned and welded to specific electrode tabs, creating multiple strong bonding points. This reduces contact resistance at each interface and improves overall electrical conductivity for charging and discharging operations.
Solution Approach 2:
Ultrasonic vibration is applied during the welding process to enhance the bonding between electrode tabs and lead member parts. The mechanical vibration cleans the contact surfaces and creates strong metallurgical bonds, reducing electrical resistance at the interfaces.
3Ease of manufacture
If ultrasonic welding is performed on continuous lead member, then welding process is simple, but vibration energy interferes between different welding points
Solution Approach 1:
The lead member is segmented into separate parts that can be welded independently. This physical separation prevents ultrasonic vibration energy from interfering between different welding points, allowing each welding operation to be performed with optimal precision without mutual interference, while the modular assembly process remains straightforward.
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 the bond strength between electrode tabs and lead members, decreasing electrical resistance and enhancing charging and discharging efficiencies, with improved charge capacity and reduced manufacturing costs.
Implementation Method 1
the electrode tabs are ultrasonically welded to the lead member
Data Source
AI summary
A secondary battery and a method of manufacturing the same in which the secondary battery includes an electrode assembly having a number of electrode plates and a number of separators. Each separator is disposed between each of the electrode plates of the plurality of electrode plates. Further included is a number of electrode tabs extending from and electrically connected to each of the plurality of electrode plates. The electrode tabs form a stack of electrode tabs by placing each electrode tab of the plurality of electrode tabs one upon another. Still further included is a number of lead members having two ends in which a first end has a space that forms a first part and a second part in the first end of each lead member with the first part and the second part are independent and separate from each other. In addition, the first part and the second part of each lead member are each coupled to the stack of electrode tabs within the battery case.