Battery Tab Connector Structure for Welding Yield and Current Flow
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Solution Overview
Problem
Increasing the thickness of the connecting piece to enhance current conduction area in battery cells leads to higher welding process requirements, affecting the welding yield and increasing material costs and weight, which is not conducive to improving the energy density.
Innovation Solution
A battery cell design with a connecting piece featuring a thinned region and a base body, where the thinned region is welded to the conductive terminal and the base body is connected to the tab, allowing independent configuration of thickness based on welding and current conduction needs, reducing material consumption and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of the connecting piece is increased to increase the current conduction area, then the current conduction capability is improved, but the welding difficulty increases and welding yield decreases
Solution Approach 1:
The connecting piece is designed with different thickness regions: a thicker base body for current conduction and a thinner welding portion for easier welding. This local differentiation allows the thick base body to provide sufficient current conduction area while the thin welding portion reduces welding difficulty and improves welding yield.
Solution Approach 2:
The connecting piece is segmented into functionally distinct regions with different thicknesses. The base body portion has greater thickness optimized for electrical conduction, while the welding portion has reduced thickness optimized for laser welding performance, allowing each region to be independently optimized for its specific function.
2Quantity of substance
If the thickness of the connecting piece is increased to increase the current conduction area, then the current conduction capability is improved, but the material cost and weight increase
Solution Approach 1:
Instead of uniformly increasing the thickness of the entire connecting piece, only the base body region is thickened to provide sufficient current conduction area. The welding portion maintains a thinner profile, reducing overall material consumption and weight while still achieving the required electrical conduction performance.
Solution Approach 2:
The connecting piece is divided into regions with different thickness requirements. The base body is segmented to have greater thickness for current conduction, while other portions are thinner, optimizing the distribution of material to match functional requirements and minimizing unnecessary weight.
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
Ensures high welding yield and reduces material costs and weight, improving the energy density of the battery cell while meeting current conduction requirements.
Implementation Method 1
the cell tabs are connected to the top cover through connecting pieces, usually by laser penetration welding
Data Source
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AI summary
The present application relates to the technical field of batteries, and discloses a single battery, comprising battery cells, a top cover, and connection members. Tabs extend out from one end of each battery cell; the top cover comprises conductive terminals; the connection members each comprise a base body and a thinned region, and the thickness of the thinned region is smaller than that of the base body; the conductive terminals are welded to the thinned regions; and the tabs are welded to the base bodies. The connection members are connected to the conductive terminals by means of the thinned regions, and are connected to the tabs by means of the base bodies. The thickness of the base bodies does not affect the welding between the thinned regions and the conductive terminals. Therefore, the structure and thickness of the thinned regions can be rationally configured according to welding requirements. The thickness of the base bodies is rationally configured according to current passing requirements, thereby avoiding the effect of the increase in the current passing area of the connection members on the yield of welding between the connection members and the conductive terminals. In addition, the thinned regions realize the reduction of local thickness, thereby reducing the amount of a material, facilitating the reduction of the material cost, reducing the weight, facilitating the improvement of the weight energy density of single batteries, and implementing high-energy-density single batteries.