Secondary Battery Multi-Tab Tack Welding for Vibration Resistance
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Solution Overview
Problem
Secondary batteries face challenges in withstanding vibrations and impacts, and existing manufacturing methods require additional bending processes that complicate the production process.
Innovation Solution
A manufacturing method for secondary batteries that involves tack welding multi-tabs using a horn and anvil with protrusion and recess parts, forming bending parts in the tabs, and welding lead tabs to these regions, which simplifies the process and enhances the battery's ability to absorb impacts and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional bending processes are used to form bending parts in multi-tabs, then the battery can withstand vibrations and impacts, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines the bending process and welding process into a single integrated operation. The welding tool simultaneously forms the bending part in the multi-tab and performs welding in one step, eliminating the need for separate bending and welding processes. This merging of operations resolves the contradiction by maintaining vibration resistance (through bending parts) while reducing manufacturing process complexity.
Solution Approach 2:
The bending parts are formed during the welding process itself, rather than as a preliminary separate step. The welding tool is designed to create the bending shape and complete the welding operation in one action, performing the bending action preliminarily within the welding operation timeframe.
2Ease of manufacture
If multi-tabs are tack welded without forming bending parts, then the manufacturing process is simpler, but the battery cannot effectively relieve vibrations and impacts
Solution Approach 1:
The patent merges the bending function and welding function into a single integrated tool and operation. The welding tool includes features that simultaneously create bending parts in the multi-tab and perform the welding operation, achieving both vibration protection and manufacturing simplicity through process integration.
Solution Approach 2:
The welding tool is designed with multi-functionality, serving both to form bending parts and to perform welding in one operation. This universal tool eliminates the need for separate bending equipment and processes, resolving the contradiction between manufacturing simplicity and vibration resistance.
3Manufacturing precision
If separate bending and welding processes are used, then the bending parts can be precisely formed, but the production time increases
Solution Approach 1:
The patent combines bending and welding into one simultaneous operation using an integrated welding tool. This merging maintains manufacturing precision because the tool is specifically designed to form accurate bending parts while performing welding, all within a single operation that reduces production time.
Solution Approach 2:
The welding operation continues without interruption to perform both bending and welding functions. The useful action of forming bending parts and welding occurs continuously in one operation rather than being divided into separate sequential steps, thereby improving productivity while maintaining precision.
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 method effectively relieves vibrations and impacts on secondary batteries while simplifying the manufacturing process by eliminating the need for additional bending steps, improving the battery's structural integrity and production efficiency.
Implementation Method 1
The multi-tab tack welding may be performed by ultrasonic welding using a horn and an anvil
Data Source
AI summary
A method of manufacturing a secondary battery and a secondary battery manufactured by the method are disclosed. In one aspect, the method includes providing an electrode assembly including first and second electrode plates, wherein the first electrode plate includes a plurality of first multi-tabs outwardly extending from an end thereof, and wherein the second electrode plate includes a plurality of second multi-tabs outwardly extending from an end thereof. The method also includes tack welding the first and second multi-tabs with the use of upper and lower welding tools, wherein the upper welding tool has a protrusion and the lower welding tool has a recess, and wherein a bending portion is formed in the first and second multi-tabs. The method further includes and welding lead tabs to the tack welded first and second multi-tabs, respectively and accommodating the electrode assembly having the lead tabs welded thereto in a case.