Battery Tab Bundle Bonding via Deviated Lead Segmentation
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Solution Overview
Problem
In batteries with multiple current collecting tabs of the same polarity, ensuring efficient and firm bonding of tab bundles to leads is challenging due to the complexity of tab bundle formation and positioning.
Innovation Solution
The battery design involves tab bundles of the same polarity protruding from the electrode group, bonded to leads at deviated positions in the thickness direction, with bonding plates and bridge plates facilitating efficient bonding and insulation, allowing for reduced tab bundle length and enhanced bondability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple current collecting tabs are bundled to form tab bundles, then the number of tabs per bundle increases, but bonding efficiency and firmness deteriorate
Solution Approach 1:
The lead is divided into multiple bonding plates arranged in the thickness direction, with each bonding plate bonding to a specific tab bundle. This segmentation allows independent optimization of each bonding interface, ensuring reliable bonding even when multiple tabs are bundled together.
Solution Approach 2:
The patent utilizes the thickness direction of the electrode group as an additional dimension for arranging bonding plates. By distributing tabs and bonding plates along the thickness direction, the patent achieves efficient bonding of multiple tabs without compromising bonding firmness, transforming a two-dimensional bonding problem into a three-dimensional arrangement.
2Device complexity
If multiple tab bundles are formed, then the complexity of bonding positions increases, but bonding efficiency decreases
Solution Approach 1:
The current collecting tabs are pre-bundled into tab bundles with specific arrangements before bonding to the lead. This preliminary organization of tabs into bundles simplifies the subsequent bonding process, as entire bundles can be bonded systematically to corresponding bonding plates rather than bonding individual tabs separately.
Solution Approach 2:
The bonding plates serve as intermediary elements between the tab bundles and the lead body. Each bonding plate acts as a mediator that facilitates the bonding connection between specific tab bundles and the lead, simplifying the overall bonding structure and improving bonding efficiency through standardized intermediate components.
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 enhances the efficiency and firmness of bonding tab bundles to leads, reducing the number of current collecting tabs needed in each bundle and improving electrical connections between the electrode group and terminals.
Implementation Method 1
The tab bundle of the current collecting tabs is bonded to the lead, for example, through ultrasonic welding.
Data Source
AI summary
In one embodiment, a battery includes an exterior unit, an electrode group, an electrode terminal, tab bundles and a lead. The electrode group is housed in an interior cavity of the exterior unit, and the electrode terminal is exposed to an outside. Current collecting tabs are stacked in the thickness direction of the electrode group in each of the tab bundles having the same polarity. The tab bundles protrude from the electrode group to the same side in the length direction of the electrode group. The lead establishes an electric connection between the respective tab bundles and the electrode terminal. The tab bundles are bonded to the lead at positions deviated from one another in the thickness direction, and are mounted on the lead from the same side in the thickness direction.