Battery Electrode Stack Structure for Stable Welding Resistance
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Solution Overview
Problem
Existing battery technologies face challenges in achieving consistent electrical resistance and stability during welding processes, leading to variations in electrical performance and potential fractures in metal layers, which affect the safety and efficiency of the battery.
Innovation Solution
The use of thermoplastic resin material as a support layer in the welding targets, combined with controlled energy application and pressure, ensures consistent electrical connection and minimizes layer fractures by forming a concave and convex region, thereby stabilizing the stack structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed on metal layers without a support layer, then electrical connection is achieved, but metal layer fractures occur and electrical resistance varies
Solution Approach 1:
The patent applies composite materials by combining metal layers with a thermoplastic resin support layer to create a multi-layer welding target. The metal layer provides electrical conductivity while the thermoplastic resin support layer provides mechanical strength and prevents fractures during welding, thereby resolving the contradiction between achieving electrical connection and maintaining metal layer integrity.
Solution Approach 2:
The thermoplastic resin support layer acts as an intermediary between the metal layers, providing a stable substrate that prevents direct stress concentration on the metal layers during welding. This intermediary layer absorbs mechanical stress and prevents metal layer fractures while maintaining electrical connection consistency.
2Reliability
If thermoplastic resin material is used as support layer, then layer fractures are minimized and structure is stabilized, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by controlling the glass transition temperature of the thermoplastic resin support layer to be higher than the welding temperature. This parameter selection ensures that the resin remains stable and does not deform during welding, providing structural stability while maintaining manufacturability through standard welding processes.
3Manufacturing precision
If glass transition temperature of thermoplastic resin is higher than welding temperature, then layer arrangement is maintained and fractures prevented, but material selection range is limited
Solution Approach 1:
The patent applies parameter changes by specifying that the glass transition temperature of the thermoplastic resin should be higher than the welding temperature. This parameter constraint ensures that the resin maintains its shape and prevents layer arrangement variations during welding, achieving manufacturing precision while allowing selection from various high-temperature-resistant thermoplastic materials.
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 enhances the safety and efficiency of the battery by reducing variance in electrical resistance and improving the life and energy density of the battery, making it suitable for applications in flight vehicles.
Implementation Method 1
when a weld point 652 is welded, the resin material 420 arranged in the weld point 652 is softened to have fluidity
Implementation Method 2
the volume expansion of the surroundings of the weld point may be suppressed
Implementation Method 3
the electrically conductive layer 642 is formed on the inner wall of the through-hole 620
Data Source
AI summary
A stack including a plurality of sheet materials that are stacked is provided. In the above-described stack, each of a plurality of sheet materials has a support layer including thermoplastic resin material, and a first metal layer and a second metal layer formed on both faces of the support layer. In a part of the plurality of sheet materials, a plurality of first metal layers and a plurality of second metal layers included in the plurality of sheet materials are integrated and each of the plurality of first metal layers and the plurality of second metal layers includes a concave and convex region where each metal layer has a bellows-like shape or a wrinkled shape.