Rechargeable Battery Support Plate Cutoff Welding
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Solution Overview
Problem
Lithium ion secondary batteries used in automobiles face challenges in maintaining safety and reliability under extreme conditions such as puncture and collapse tests, where excessive temperature increase is a concern due to inadequate weld strengths between the electrode assembly and electrode terminals.
Innovation Solution
A rechargeable battery design featuring a support plate with conductive plates and cutoff portions that enhance weld strengths between the electrode assembly and electrode terminals, allowing direct exposure of non-coating portions for easier welding and concentrated welding energy, thereby improving the structural integrity and safety during extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the support plate uses a conventional design without cutoff portions, then the structure is simpler, but the weld strength between the electrode assembly and electrode terminals is insufficient
Solution Approach 1:
The support plate is segmented by introducing cutoff portions that divide the plate into separate regions. This segmentation creates distinct welding areas between the electrode assembly and electrode terminals, allowing concentrated welding energy in each region and improving overall weld strength without significantly complicating the overall structure.
Solution Approach 2:
The cutoff portions create local variations in the support plate structure, providing specific regions with enhanced welding characteristics. The areas around the cutoff portions are designed to concentrate welding energy, creating locally optimized weld zones that improve strength where needed most.
2Ease of manufacture
If the support plate design does not expose non-coating portions, then the structure is more compact, but the welding process is less efficient and weld strength is reduced
Solution Approach 1:
The support plate is pre-designed with cutoff portions that expose the non-coating portions of the electrode assembly before the welding process begins. This preliminary exposure of welding surfaces eliminates the need for additional processing steps and allows direct welding access, significantly improving manufacturing efficiency.
3Temperature
If weld strengths are insufficient, then the battery structure is simpler, but temperature increases excessively during puncture or collapse tests
Solution Approach 1:
The cutoff portions create curved or rounded edges at the boundaries of the support plate segments. This curvature design helps concentrate and distribute welding energy more effectively, creating stronger welds that prevent excessive temperature increases during safety tests by ensuring better electrical connection and current distribution.
Data Source
Figure 1a
Figure 1b
Figure 1c~2a
AI summary
A rechargeable battery is provided comprising at least one electrode assembly (110) having a first electrode (111), a second electrode (112) and a separator (113) interposed between the first and the second electrodes (111, 112), wherein the first electrode (111) comprises a first uncoated region (111c) and the second electrode (112) comprises a second uncoated region (112c), a case (120) for mounting the at least one electrode assembly (110) therein; and a cap plate (150) for covering an opening of the case (120). Further, a support plate (160) is provided between the electrode assembly (110) and the case (120), the support plate (160) including at least one conductive plate (161) electrically coupled to the first or second uncoated region (111c, 112c) of one of the at least one electrode assemblies (110), the at least one conductive plate (161) comprising at least one first portion (161 a), the first portion (161 a) having a height being smaller than the height of the first or second uncoated region (111c, 112c) the at least one conductive plate is coupled to.