Battery Pack Electrode Tab Plate Portion Laser Welding
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Solution Overview
Problem
Existing battery pack configurations face challenges in achieving suitable laser welding of electrode tabs and bus bars when increasing laser output to improve welding quality, as the laser may penetrate the electrode tabs, leading to suboptimal connections.
Innovation Solution
The battery pack design includes unit cells with a flat cell body and extending electrode tabs, where the cathode-side electrode tab has a plate portion formed by folding its distal end to prevent laser penetration, allowing for improved laser welding even with increased laser output, and the bus bars are connected using laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser output is increased to improve welding quality, then welding quality is improved, but the laser penetrates the electrode tabs causing unsuitable welding
Solution Approach 1:
A plate portion is introduced as an intermediary component between the laser beam and the electrode tab. This plate portion reflects the laser beam away from the electrode tab, preventing direct laser penetration while allowing the welding process to proceed with higher laser output for improved welding quality.
Solution Approach 2:
The configuration changes the physical arrangement by adding a plate portion that forms a stacked structure with the electrode tab along the laser irradiation direction. This structural parameter change enables the system to tolerate higher laser output without penetration, as the plate portion intercepts and reflects the laser energy.
2Reliability
If laser output is increased to improve welding quality, then welding quality is improved, but suitable welding cannot be achieved due to penetration
Solution Approach 1:
The plate portion serves as a mediator that enables the use of higher laser output for improved welding reliability while preventing the harmful penetration effect that would otherwise make the welding process unsuitable.
3Quantity of substance
If electrode tabs are connected to bus bars by laser welding, then electrical connection is achieved, but laser penetration occurs reducing connection quality
Solution Approach 1:
The plate portion acts as an intermediary that protects the electrode tab from direct laser exposure during the welding process, enabling high-quality electrical connections to be formed between the electrode tab and bus bar without penetration defects.
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 configuration enables suitable laser welding of electrode tabs and bus bars, preventing laser penetration and ensuring high-quality connections, while also aligning the positions of bus bars for easier welding and reducing current resistance.
Implementation Method 1
the connection between the electrode tabs and the bus bars is carried out by laser welding
Implementation Method 2
when connecting the electrode tabs and the bus bars by laser irradiation
Data Source
AI summary
A battery pack has a plurality of unit cells, a bus bar and a plate portion. The unit cells each includes a cell body having a power-generating element and being formed in a flat shape. Each unit cell has an electrode tab that extends out from a corresponding one of the cell bodies. The unit cells are stacked in a thickness direction of the cell bodies. The bus bar is electrically connected to the electrode tabs by laser welding. The plate portion forms a stacked structure together with the electrode tabs along an irradiation direction of the laser. Each electrode tab includes an anode-side electrode tab and a cathode-side electrode tab. The cathode-side electrode tabs have a different thickness than the anode-side electrode tabs. The plate portion is only provided on the ones of the anode-side electrode tabs and the cathode-side electrode tabs that have a smaller thickness.