Battery Tab Flattening for Stable Pole Column Welding
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Solution Overview
Problem
The existing battery manufacturing process faces difficulties in connecting the bent tab portion with the pole column subassembly due to configuration limitations, leading to instability and safety risks during welding.
Innovation Solution
The battery design includes a housing with two opposite surfaces, a cell with single-piece tabs extending from the lateral side, and a pole column subassembly arranged on one surface, where the tabs are flattened and overlapped to facilitate direct welding, enhancing structural stability and safety by ensuring the tab portion and pole column subassembly are partially overlapped, allowing for efficient connection using methods like laser, ultrasonic, or resistance welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tab portion is bent to connect with the pole column subassembly, then the connection can be achieved, but the welding stability and safety are compromised due to configuration limitations
Solution Approach 1:
Instead of bending the tab portion to achieve connection, the patent inverts the approach by making the pole column subassembly adaptable to the tab's original position. The pole column subassembly is designed with a receiving structure that accommodates the tab portion without requiring bending, thus maintaining welding stability while achieving connection.
Solution Approach 2:
The patent applies parameter changes by modifying the geometric parameters of the pole column subassembly to match the tab portion's dimensions and position. The receiving structure's size and shape are adjusted to perfectly accommodate the tab, enabling direct welding without bending and ensuring both connection feasibility and welding stability.
2Ease of manufacture
If the tab portion is bent for connection, then the assembly can be completed, but structural stability deteriorates
Solution Approach 1:
The patent inverts the conventional approach by not bending the tab portion but instead designing the pole column subassembly to receive the tab in its original position. This eliminates the bending operation that compromises structural stability while still achieving complete assembly.
Solution Approach 2:
The pole column subassembly is pre-designed with a receiving structure that anticipates the tab portion's position and dimensions. This preliminary design ensures that when the tab is inserted, it fits perfectly without requiring bending, thereby maintaining structural stability throughout the assembly process.
3Device complexity
If the cover plate configuration is fixed, then manufacturing is simplified, but the ability to connect bent tabs is limited
Solution Approach 1:
The patent applies local quality by making only the pole column subassembly adaptable while keeping the cover plate configuration fixed. The receiving structure of the pole column subassembly is locally designed to accommodate the tab portion, allowing connection capability to improve without increasing overall device complexity.
Solution Approach 2:
The pole column subassembly is designed with multi-functionality, serving both as a structural component and as an adaptive connection interface. The receiving structure enables it to accommodate tab portions with varying positions and dimensions, providing versatility without requiring changes to the cover plate configuration.
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
The disclosure provides a battery, a battery module, a battery pack, and a battery manufacturing method. The battery includes a housing (10), a cell (20), and a pole column subassembly (30). The housing (10) includes two first surfaces (11) opposite to each other in a first direction. The cell (20) is arranged in the housing (10). The cell (20) includes a cell body (21) and a tab portion (22). The tab portion (22) includes two or more single-piece tabs (221) extending from the lateral side of the cell body (21). When the single-piece tabs (221) are flattened along the direction perpendicular to the lateral side of the cell body (21), the overlapping direction of the single-piece tabs (221) is the first direction. The pole column subassembly (30) is arranged on a first surface (11) and connected with the tab portion (22). The orthographic projections of the tab portion (22) and the pole column subassembly (30) along the first direction are at least partially overlapped on a first surface (11).