Battery Cell Tab Bending and Welding for Compact Converging
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Solution Overview
Problem
Conventional lithium ion battery manufacturing processes face inefficiencies in welding and converging battery cell tabs, leading to increased material consumption, complex welding processes, and potential dislocation and deformation of tabs during assembly.
Innovation Solution
A method and device for welding and converging battery cell tabs involve laminating a plate set with positive and negative tabs, bending the tabs to form bends, and then converging and welding them using a mould pressing mechanism and welding assembly, reducing tab lengths and improving alignment and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional welding and converging processes are used for battery cell tabs, then the welding process is complex and time-consuming, but the manufacturing efficiency is low and material consumption is high
Solution Approach 1:
The patent combines the welding and converging processes into a single integrated operation. The welding assembly performs both welding and converging actions simultaneously on the tabs, eliminating the need for separate welding and converging steps. This merging of operations directly reduces process complexity and improves manufacturing efficiency by completing multiple functions in one step.
Solution Approach 2:
The patent applies preliminary bending to the tabs before the welding operation. The mould pressing mechanism pre-forms the tab shapes and positions them correctly prior to welding. This preliminary action ensures proper alignment and reduces the complexity of the subsequent welding process, as the tabs are already in their final converged positions when welding occurs.
2Loss of substance
If conventional tab lengths are used in battery assembly, then the tabs provide sufficient connection length, but the material cost is high and space utilization is poor
Solution Approach 1:
The patent changes the physical parameters of the tabs by bending them into converged shapes. Instead of using long straight tabs, the mould pressing mechanism transforms them into compact bent shapes with optimized geometry. This parameter change allows the tabs to maintain sufficient electrical connection length while reducing the overall material consumption and improving space utilization within the battery cell.
3Reliability
If tabs are not bent and converged during laminating, then the process is simple, but tab dislocation and deformation occur during subsequent assembly
Solution Approach 1:
The patent performs preliminary bending and converging of the tabs during the laminating process itself. The mould pressing mechanism is integrated into the laminating line, and tabs are pre-formed to their final shapes before the battery cell assembly is completed. This preliminary action prevents tab dislocation and deformation in subsequent handling and assembly operations, as the tabs are already in their correct converged positions.
Solution Approach 2:
The patent merges the tab converging operation with the laminating process. Instead of performing converging as a separate subsequent step, the welding assembly integrates both welding and converging functions, executing them simultaneously during laminating. This merging ensures tab alignment is established early in the process, preventing dislocation while avoiding the need for separate complex converging equipment.
4Productivity
If welding is performed after complete assembly, then all components are in position, but the overall process efficiency is reduced
Solution Approach 1:
The patent performs the welding operation at an earlier stage in the manufacturing process, during the laminating step rather than after complete assembly. By executing welding while the battery cell is still being formed, the process eliminates subsequent welding steps and reduces the overall manufacturing time. This preliminary welding action improves productivity by completing critical joining operations before additional assembly steps are required.
Data Source
AI summary
Disclosed are a method and device for welding and converging battery cell tabs, which is used for welding and converging battery core end faces. The method comprises: laminating to form a plate set composed of a positive plate, a separator and a negative plate by laminating, the positive plate comprising a positive tab, and the negative plate comprising a negative tab; during laminating, bending the positive tab to form a positive tab bend, and bending the negative tab to form a negative tab bend; and welding the positive tab bend of each positive plate in the plate set, and/or welding the negative tab bend of each negative plate in the plate set. Based on the method and device, a reserved length of the tab is reduced, and a material loss of the tab material is greatly reduced. Station circulation is reduced and production efficiency and a product yield are improved.