Battery Lead Tab Welding with Flattened End Part
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Solution Overview
Problem
Resistance welding between a lead and a metal plate in cell manufacturing can cause a raised end part with a sharp shape, potentially damaging flexible components like lead wires and leading to electrical failures or short circuits, due to the stress from the welding process.
Innovation Solution
The end part of the lead is flattened after resistance welding using a press die to prevent damage to adjacent components, ensuring a stable connection and reducing the risk of short circuits by maintaining a specific thickness in the connection and non-weld parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance welding is performed between a lead and a metal plate, then a stable welded area and current density are achieved, but a raised end part with a sharp shape is caused in the lead due to welding stress
Solution Approach 1:
The patent applies preliminary action by performing pressing treatment on the lead before resistance welding to pre-flatten the end part. This prevents the end part from being raised during welding, eliminating the sharp shape that could damage adjacent components while maintaining stable welding conditions.
Solution Approach 2:
The patent applies preliminary anti-action by using pressing treatment to create a flattened state that counteracts the raising effect caused by welding stress. The pre-applied compression force opposes the upward force generated during resistance welding, preventing the harmful raised end part from forming.
2Object-affected harmful factors
If the end part of the lead is pressed to flatten it, then damage to adjacent flexible components is prevented, but the thickness of the lead is reduced
Solution Approach 1:
The patent applies local quality by performing pressing treatment only on the end part of the lead, not the entire lead body. This localized treatment flattens the end part to prevent damage to adjacent components while maintaining the original thickness and properties of the main lead body.
Solution Approach 2:
The patent applies partial action by selectively pressing only the portion of the lead that would cause harm (the end part), rather than the entire lead. This partial treatment achieves the necessary protection without excessive material removal or thickness reduction.
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 solution effectively prevents damage to flexible components and ensures reliable electrical connections by flattening the raised end part of the lead, enhancing the durability and safety of the cell assembly.
Implementation Method 1
resistance welding between a lead and a metal plate
Implementation Method 2
resistance welding between a midway part of the lead, not an end part of the lead, and the metal plate
Implementation Method 3
a dent is caused in the midway part of the lead on which the resistance welding is performed, and the end part of the lead could be raised from the metal plate due to the stress caused by the resistance welding
Data Source
AI summary
An axial lead extending on a principal surface of a flat tab includes a main body part having a diameter and a connection part. The connection part includes a first part located adjacent to the main body part and a second part located from the first part and the end part. The first part includes a weld part welded to the flat tab and has a first thickness less than the diameter. The second part includes a non-weld part not welded to the flat tab and has a second thickness equal to or less than the first thickness. The second part is formed by pressing the end part of the axial lead, the end part having been raised when resistance welding is performed on the axial lead and the flat tab.