Battery Pack Tab Plate Through Hole Preheating
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Solution Overview
Problem
The existing battery pack manufacturing process faces challenges in maintaining uniform welding strength between the electrode tab and the tab plate due to varying sizes of welding beads formed during laser welding, which affects the stability of the electrical connection.
Innovation Solution
The battery pack design incorporates a tab plate with a through hole to preheat the electrode tab, and a specific laser intensity reduction method to form welding beads of consistent size, ensuring uniform welding strength by adjusting laser intensities at different stages of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is performed to connect the electrode tab and tab plate, then electrical connection is achieved, but welding bead sizes vary causing non-uniform welding strength
Solution Approach 1:
The patent applies preliminary heating to the electrode tab before laser welding by irradiating a laser beam through the through hole at reduced intensity (30% of welding intensity). This preheating action raises the temperature of the electrode tab to a state where subsequent welding produces uniform bead sizes, resolving the inconsistency in welding strength caused by varying bead sizes during the welding process
2Reliability
If multiple welding beads are formed sequentially during laser welding, then electrical connection is established, but welding strength becomes non-uniform due to varying bead sizes formed at different times
Solution Approach 1:
The through hole in the tab plate enables preliminary heating of the electrode tab before the actual welding process. By preheating the electrode tab to an appropriate temperature state, the subsequent formation of multiple welding beads produces consistent bead sizes, ensuring uniform welding strength and stable electrical connection across all weld points
3Productivity
If laser intensity is maintained at welding level throughout the process, then welding efficiency is high, but electrode tab temperature variation causes non-uniform welding beads
Solution Approach 1:
The patent employs periodic action by using two distinct laser irradiation phases: first, a preheating phase with reduced laser intensity (30% of welding intensity) through the through hole to raise electrode tab temperature; second, a welding phase with full laser intensity to form welding beads. This periodic variation in laser intensity ensures both uniform bead sizes and efficient welding execution
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 approach secures a stable and uniform welding strength between the tab plate and the electrode tab, enhancing the reliability of the electrical connection in the battery pack.
Implementation Method 1
irradiating a laser beam through the through hole to heat the electrode tab
Implementation Method 2
irradiating the laser beam onto the tab plate to form welding beads for electrically connecting the tab plate and the electrode tab
Data Source
AI summary
The present invention relates to a battery pack capable of securing a welding strength between a tab plate and an electrode tab, and a manufacturing method therefor. As an example, disclosed is a battery pack comprising: a battery cell from which an electrode tab is withdrawn; and a protection circuit module which is electrically connected to the battery cell and which has a circuit board and a tab plate formed on one surface of the circuit board and electrically connected to the electrode tab, wherein the tab plate has a through hole for heating the electrode tab.