Battery Tab-to-Busbar Laser Welding with Guided Filler Wire
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Solution Overview
Problem
Existing secondary battery welding technologies face challenges in reliably connecting battery cells to busbars, particularly due to variations in lead tab portion lengths affecting weld quality.
Innovation Solution
A battery manufacturing apparatus and method utilizing a welding wire, supply portion, guiding portion, and laser irradiation to weld lead tab portions and busbars, with a cutting and blocking portion to ensure consistent and reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods are used to connect battery cells to busbars, then the welding process is simple, but the welding performance varies depending on lead tab portion length affecting reliability
Solution Approach 1:
A welding wire is introduced as an intermediary material between the lead tab portion and the busbar. The welding wire is supplied from a supply portion and guided by a guiding portion to ensure consistent positioning and length regardless of the lead tab portion length, thereby achieving reliable welding across variations in lead tab dimensions
Solution Approach 2:
The welding wire is pre-supplied and pre-positioned using the supply portion and guiding portion before the actual welding process. This preliminary action ensures that the welding wire is correctly aligned and positioned regardless of lead tab length variations, enabling consistent welding performance without requiring adjustment for each lead tab length
2Reliability
If welding wire is supplied to ensure consistent welding quality, then welding reliability improves, but device complexity increases
Solution Approach 1:
The supply portion and guiding portion are designed as universal components that can accommodate various lead tab portion lengths without requiring modification. These components perform multiple functions: supplying welding wire, guiding it to the correct position, and ensuring consistent welding quality across different battery cell configurations, thereby justifying the added complexity through enhanced reliability and versatility
Solution Approach 2:
The guiding portion is designed to dynamically adapt to different lead tab portion lengths while maintaining consistent welding wire positioning. The system can adjust its operation to accommodate variations in lead tab dimensions, ensuring reliable welding without requiring complex reconfiguration for each case
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
Enables quick and reliable welding of battery cells to busbars, independent of lead tab portion length, enhancing weld stability and performance.
Implementation Method 1
a laser irradiation portion irradiating the lead tab portion, the busbar, or the welding wire with a laser
Implementation Method 2
at least a portion of which is melted to weld the lead tab portion and the busbar
Data Source
AI summary
A battery manufacturing apparatus for manufacturing a battery assembly including a plurality of battery cells, each having a lead tab portion electrically connected to an outside and protruding outwardly, and a busbar electrically connecting one or more battery cells among the plurality of battery cells of the present disclosure includes a welding wire, at least a portion of which is melted to weld the lead tab portion and the busbar, a supply portion supplying the welding wire to the lead tab portion, a guiding portion contacting the welding wire discharged from the supply portion and moving the welding wire in a direction in which the lead tab portion extends, and a laser irradiation portion irradiating the lead tab portion, the busbar, or the welding wire with a laser.