Lithium Battery Electrode Tab Structure for Easier Cell Replacement
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Solution Overview
Problem
The existing methods for assembling and reassembling large lithium batteries are time-consuming and prone to damaging electrode tabs, leading to poor soldering quality when replacing malfunctioned cells, as they require peeling off and re-soldering electrode tabs, which can also damage normal cells.
Innovation Solution
The lithium battery design includes electrode tabs with a first and second conductive sheet, where only the first conductive sheets are soldered together, allowing for the direct cutting and replacement of the first sheet without disturbing the second sheet's soldering point, enabling efficient reassembly by using the second sheet for re-soldering, thus avoiding poor soldering quality and cell damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If electrode tabs are pealed off and re-soldered when replacing malfunctioned cells, then cell replacement can be performed, but the process is time consuming and damages electrode tabs leading to poor soldering quality
Solution Approach 1:
The electrode tab is segmented into a first conductive sheet and a second conductive sheet. The first conductive sheet is designed to be cut off and discarded, while the second conductive sheet remains soldered to the battery body. This segmentation allows the malfunctioned cell to be replaced by simply cutting and removing the first conductive sheet, eliminating the time-consuming peeling process while preserving the soldering joint on the second conductive sheet.
2Ease of repair
If electrode tabs are pealed off for cell replacement, then malfunctioned cells can be replaced, but electrode tabs of normal cells are damaged leading to poor soldering quality
Solution Approach 1:
The electrode tab is divided into two functional parts: a first conductive sheet that is temporarily attached and can be cleanly cut off, and a second conductive sheet that remains permanently soldered to the battery body. This segmentation ensures that when a malfunctioned cell is replaced, only the first conductive sheet needs to be removed, leaving the second conductive sheet's soldering joint intact and undamaged, thus maintaining high soldering quality.
3Ease of repair
If electrode tabs are repeatedly soldered at the same point, then cell replacement is possible, but soldering quality deteriorates and cells may be damaged
Solution Approach 1:
The electrode tab structure separates the temporary connection function (first conductive sheet) from the permanent connection function (second conductive sheet). During cell replacement, the first conductive sheet is cut off and discarded, while the second conductive sheet remains soldered in place. This allows repeated assembly operations to occur at the first conductive sheet's location without repeatedly heating and re-soldering the same joint, thereby maintaining soldering joint reliability.
4Reliability
If the entire electrode tab is soldered for strong connection, then electrical connection is reliable, but replacement requires damaging the tab structure
Solution Approach 1:
The electrode tab is segmented into a first conductive sheet and a second conductive sheet with different functions. The second conductive sheet provides the reliable, permanent electrical connection through soldering to the battery body, while the first conductive sheet provides a temporary connection that can be easily cut off for replacement. This segmentation achieves both reliable electrical connection and ease of repair.
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 design facilitates easy and efficient reassembly of lithium batteries by allowing direct cutting and re-soldering of the first conductive sheet, preventing damage to normal cells and ensuring better soldering quality without the need to re-solder at the same point, making the process more reliable and efficient.
Implementation Method 1
each electrode tab is soldered with a corresponding electrode tab of another cell, the first conductive sheets and the second conductive sheets of the two electrode tabs correspondingly soldered with each other are respectively arranged in pair
Data Source
AI summary
A lithium battery includes multiple cells. Each cell includes a body and a pair of electrode tabs. In each cell, the pair of electrode tabs is arranged on one side of the body. Each electrode tab is outwardly extended from the body. Each electrode tab includes a first conductive sheet and at least one second conductive sheet, which are arranged side by side. In each cell, each electrode tab is soldered with a corresponding electrode tab of another cell, the first conductive sheets and the second conductive sheets of the two electrode tabs correspondingly soldered with each other are arranged in pairs, and only the two first conductive sheets are correspondingly soldered with each other.