Battery Pack Connection Tab Welding
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Solution Overview
Problem
Existing battery pack connection methods, such as soldering, face challenges with uniform quality, potential for short circuits, and poor bonding due to material properties, particularly with aluminum electrode tabs, leading to reduced coupling strength and increased risk of galvanic corrosion.
Innovation Solution
A battery pack design utilizing a connection tab structure with a pair of first and second connection tab portions, made of the same material, to couple with electrode tabs of different materials, ensuring a maximum of three layers in the coupling portion and using welding for automated, uniform coupling, preventing overlap and enhancing mechanical and electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect electrode tabs, then electrical connection is achieved, but coupling strength is reduced and galvanic corrosion risk increases
Solution Approach 1:
The patent introduces a connection tab as an intermediary component made of a third material that is different from both the connection tab material and the electrode tab material. This intermediate connection tab prevents direct contact between dissimilar materials, thereby eliminating galvanic corrosion risks while providing strong mechanical coupling through welding. The connection tab acts as a mediator that resolves the material incompatibility issue.
2Ease of manufacture
If material-specific bonding methods are used for different electrode tab materials, then bonding is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent employs homogeneous welding methodology to join all components (electrode tabs and connection tabs) regardless of their material composition. By using a universal welding process for all material combinations, the manufacturing process is simplified and standardized, eliminating the need for multiple specialized bonding methods for different material pairs.
Solution Approach 2:
The connection tab structure serves multiple functions: it provides mechanical support, enables electrical connection, and facilitates welding assembly. This multi-functional design allows a single component to address various requirements, simplifying the overall manufacturing process by reducing the need for separate specialized components or processes.
3Weight of moving object
If electrode tabs are made of aluminum, then weight is reduced, but welding performance deteriorates
Solution Approach 1:
The patent employs a composite material structure where the connection tab is made of a third material that is weldable, while the electrode tabs can be made of lightweight materials like aluminum. This composite approach allows each component to be made from the most suitable material for its specific function, optimizing both weight and manufacturability.
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 improves coupling strength, reduces electrical resistance, and prevents back-bead defects, ensuring reliable electrical connections and increased output power by distributing welding energy evenly and maintaining high-quality welds without material-specific bonding issues.
Implementation Method 1
The electrode tab and the connection tab may be coupled together by welding.
Data Source
AI summary
A battery pack, including a battery cell including an electrode tab; a cell holder through which the electrode tab is inserted; and a connection tab including a first connection tab portion and a second connection tab portion facing each other and coupled to the electrode tab with the electrode tab being therebetween.