Battery Connection Tab Folded Around Insulator
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Solution Overview
Problem
In secondary battery manufacturing, series spot welding faces challenges with reduced welding force when dealing with thick materials, which affects the efficiency and reliability of connecting multiple cells, especially in narrow spaces.
Innovation Solution
The implementation of a method involving a connection tab with positive and negative electrode leads, where electrode tabs of bare cells are either directly or series spot-welded to these leads, and a protective circuit module (PCM) is coupled to control charging and discharging, with the connection tab being folded to ensure parallel alignment and contact of cells, and optionally surrounded by a cover layer for enhanced electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If series spot welding is used to connect electrode tabs in narrow spaces, then ease of operation is improved, but welding force decreases when welding length increases due to thick materials
Solution Approach 1:
An insulator is introduced as an intermediary component between the connection tab and the electrode tabs of the bare cells. The insulator provides a structured interface that enables reliable series spot welding in narrow spaces while maintaining adequate welding force through proper positioning and contact area management.
Solution Approach 2:
The insulator is pre-positioned on the connection tab before the welding process. This preliminary action ensures proper alignment and contact between the connection tab and electrode tabs, enabling effective welding in constrained spaces without compromising welding force.
2Manufacturing precision
If connection tab is folded around insulator, then manufacturing precision is improved for parallel alignment, but device complexity increases
Solution Approach 1:
The connection tab is folded into a U-shape curved structure around the insulator. This curvature enables the connection tab to wrap around the insulator and achieve parallel alignment of the bare cells, improving manufacturing precision through geometric constraint.
3Reliability
If cover layer surrounds connection tab, then reliability is improved for electrical insulation, but manufacturing precision requirements increase
Solution Approach 1:
A cover layer is used to surround the connection tab and insulator assembly. This flexible protective layer provides electrical insulation and physical protection, improving reliability while accommodating the folded structure of the connection tab.
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 approach enhances the workability and reliability of connecting multiple secondary battery cells, maintaining high voltage and output capacity while allowing for efficient charging and discharging, even in constrained spaces, by ensuring strong electrical connections and parallel alignment of cells.
Implementation Method 1
The principle is that members to be welded are melted and welded by Joule heat generated when current flows through the members for a short time
Data Source
AI summary
A secondary battery in which electric connection between an electrode tab of a bare cell and a connection tab of a protective circuit module is performed by welding the electrode tab of the bare cell to the connection tab of the protective circuit module that form a battery pack. A process is provided so that electrode tabs of two or more laminated bare cells are easily and precisely welded to a single, or more, connection tabs by a worker. The welding process is effectively performed and welding strength between the tabs increases.