Battery Cell Tab Connection Structure for Drop Impact Resistance
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Solution Overview
Problem
Current battery cell designs are prone to tab failure due to loose welds caused by impact forces from accidental drops.
Innovation Solution
The battery cell incorporates a connecting piece that is flexibly bendable and indirectly connects the tab to the current collector, allowing the connecting piece to absorb and distribute impact forces, thereby reducing the risk of loose welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tab is directly welded to the current collector, then the connection is strong and reliable under normal conditions, but the welding position is prone to damage under impact force causing tab failure
Solution Approach 1:
A connecting piece is introduced as an intermediary component between the tab and the current collector. This connecting piece includes a fixed end connected to the current collector and a free end that is flexibly bendable. The tab is fixed to the free end of the connecting piece, creating an indirect connection that allows the connecting piece to absorb and distribute impact forces, thereby protecting the weld joints from damage.
Solution Approach 2:
The connecting piece is designed with flexible bendability, allowing it to dynamically respond to impact forces. When impact occurs, the connecting piece can deform elastically rather than transmitting the full force to the weld joints. This dynamic flexibility transforms the rigid direct connection into a resilient indirect connection that adapts to external forces.
2Object-affected harmful factors
If a connecting piece is introduced to protect against impact, then the resistance to impact force improves, but the device complexity increases
Solution Approach 1:
The connecting piece is integrally formed with the current collector, combining two components into one. This integral structure eliminates the need for separate attachment mechanisms while maintaining the protective function. The tab connection structure is merged with the current collector body, reducing the number of discrete parts and simplifying the overall structure.
Solution Approach 2:
The connecting piece utilizes a thin, flexible structure that can bend and deform under impact. This thin-film approach provides protective functionality without adding significant bulk or complexity. The flexible nature of the connecting piece allows it to absorb impact energy while maintaining a compact form factor that integrates smoothly with the existing electrode plate design.
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 effectively reduces the risk of tab failure due to drops by transferring impact forces to the connecting piece and absorbing energy, ensuring the tab remains securely attached to the current collector.
Implementation Method 1
The free end is flexibly bendable against the current collector
Implementation Method 2
the free end is disposed toward the connected flat portion and is close to or fits snugly with the connected flat portion, and the free end is flexibly bendable against the current collector
Data Source
AI summary
A battery cell includes an electrode assembly and a housing accommodating the electrode assembly. The electrode assembly includes a first electrode plate and a second electrode plate. The first electrode plate includes a current collector, a connecting piece, and a tab. The current collector includes a plurality of stacked flat portions. A fixed end of the connecting piece is connected to one of the flat portions. A free end of the connecting piece is disposed toward the flat portion. The free end is flexibly bendable against the current collector. A first end of the tab is fixed to the connecting piece, and a second end of the tab is disposed beyond the flat portion.