Battery Pack Electrode Tab Coupling Regions
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Solution Overview
Problem
Battery packs with multiple unit cells face challenges in maintaining a stable electrical connection, which is crucial for high power and long-term operation in devices like electric vehicles and notebook computers, due to insufficient heat adhesion between electrode tabs and lead members.
Innovation Solution
The battery pack design incorporates specific coupling regions for electrode tabs and lead members, where resistance welding is used to create separate contact points, ensuring sufficient heat adhesion and increased connection strength by forming distinct coupling regions for inter-unit cell and lead member connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple unit cells are electrically connected to increase output voltage or current, then the power and capacity of the battery pack are improved, but the connection strength between unit cells deteriorates due to insufficient heat adhesion
Solution Approach 1:
The patent divides the connection structure into distinct segments: separate coupling regions for inter-unit cell connections and lead member connections. Each coupling region is independently formed, allowing optimized welding parameters for each connection type. This segmentation prevents heat interference between different connection points and ensures sufficient heat adhesion for each individual connection.
Solution Approach 2:
The patent applies different connection qualities to different locations: the first coupling region (inter-unit cell) and second coupling region (lead member) have distinct welding characteristics and thermal properties. Each region is designed with specific local qualities - such as varying welding current, duration, or electrode pressure - to achieve optimal heat adhesion for that particular connection type, thereby resolving the contradiction between power scaling and connection strength.
2Reliability
If electrode tabs are extended and connected to multiple components, then the electrical connection status is improved, but the connection stability deteriorates due to insufficient heat adhesion
Solution Approach 1:
The connection system is segmented into multiple independent coupling regions along the electrode tab. Each coupling region (first coupling region for unit cells, second coupling region for lead member) is separately formed with dedicated welding parameters. This segmentation ensures that each connection point achieves sufficient heat adhesion independently, preventing connection instability that would result from overloaded or improperly distributed thermal energy.
Solution Approach 2:
The patent performs preliminary welding actions at specific coupling regions before final assembly completion. By pre-forming the first coupling region between unit cells and the second coupling region with the lead member, the electrode tab is pre-stabilized with proper heat adhesion. This preliminary action prevents subsequent connection instability and ensures reliable electrical connection status throughout the battery pack assembly process.
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 enhances the connection strength and stability between unit cells and the lead member, preventing weak connections and ensuring reliable power transmission and extended operational performance.
Implementation Method 1
resistance welding is used to create separate contact points, ensuring sufficient heat adhesion and increased connection strength
Implementation Method 2
resistance welding is used to create separate contact points
Data Source
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AI summary
In a battery pack according to one or more embodiments of the present invention, a connection strength between a plurality of embedded unit cells is reinforced, whereby an electrical connection status is stabilized.