Battery Cell Tab Dowel Structure for Reliable Electrode Welding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Lithium-ion batteries face challenges in maintaining thermal, chemical, and physical stability under various abuse conditions, which can lead to internal temperature increases and undesirable reactions, affecting performance and longevity.

Innovation Solution

The use of cathode and anode dowels that engage with respective cathode and anode tabs in parallel within an enclosure, forming improved connections to prevent damage and tears, and are connected to output terminals for a battery pack.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional connection methods are used for electrode tabs, then the manufacturing process is simpler, but the connection reliability and resistance to damage under abuse conditions is reduced

Engineering Contradiction:

Improveconnection reliabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The dowel is pre-positioned through the electrode tab before the tab is folded and welded. This preliminary placement ensures proper alignment and positioning, preventing misalignment issues that could compromise connection reliability under thermal and mechanical stress.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connection structure is divided into distinct functional segments: the dowel provides mechanical support and alignment, the folded tab creates a secure mechanical interlock, and the weld provides electrical and structural bonding. This segmentation allows each component to optimize its specific function, improving overall connection reliability.

Inventive Principle:

Principle #1Segmentation

2Reliability

If electrode tabs are connected without protective structures, then the manufacturing process is faster, but the tabs are susceptible to damage and tears under abuse conditions

Engineering Contradiction:

Improvetab damage resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The dowel acts as a protective cushioning element positioned behind the electrode tab. During abuse conditions such as impact or thermal expansion, the dowel absorbs and distributes mechanical stresses, preventing direct damage to the tab material and reducing the risk of tears or deformation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The dowel is nested within the battery structure, with the electrode tab folded around it. This nested configuration provides structural support to the tab while maintaining a compact design. The dowel is positioned within the recess formed by the folded tab, creating a protected, integrated structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Strength

If the dowel structure is implemented, then connection strength and tab protection are improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveconnection strengthVSAvoiddowel alignment precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The dowel is positioned in a specific recess area of the electrode assembly, concentrating the structural support function at the critical connection point. This localized placement provides maximum strength where needed most, while the recess geometry guides proper dowel positioning, reducing the overall precision requirements for the entire manufacturing process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The recess structure acts as an intermediary element between the dowel and the electrode tab. It provides a predefined positioning feature that guides the dowel into correct alignment during assembly, reducing the precision requirements for direct dowel-to-tab alignment while ensuring proper final positioning for optimal connection strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enhances battery longevity and performance by preventing damage to tabs and improving connection reliability, thereby ensuring stable operation under normal and abuse conditions.

Implementation Method 1

the dowel is glued to a corresponding one of the cathode tab or the anode tab on each of the electrodes

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS20250385399A1Battery cell with dowel for welding electrode tabs

Publication Date: 2025.12.18 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A secondary battery cell includes a battery cell receptacle and an electrode assembly having multiple electrodes with each of the electrodes including a cathode tab and an anode tab. The electrode assembly is at least partially enclosed within the battery cell receptacle. The secondary battery cell includes a dowel extending through a tab dowel opening in at least one of the cathode tab or the anode tab on each of electrodes and a cap assembly having a cathode portion connecting the cathode tab on each of the electrodes to a negative terminal, an anode portion connecting the anode tab on each of the electrodes to a positive terminal, and a cap at least partially forming a battery enclosure for the electrode assembly with the battery cell receptacle. The dowel also forms a portion of a connection in one of the cathode portion or the anode portion.