Battery Tab Connection Structure for Compact Laser-Welded Assemblies
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Solution Overview
Problem
Existing electrochemical assemblies face challenges in achieving a reliable, economical, and compact connection between electrodes and terminals, which are often complex and costly to manufacture.
Innovation Solution
The electrochemical assembly features a first common connection element with electrical connection ribs and support elements that are laser-welded to the electrical connection tabs, extending parallel to the stacking plane, forming a compact and symmetrical structure that ensures reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods are used between electrodes and terminals, then reliable electrical connection can be achieved, but the manufacturing process becomes complex and costly
Solution Approach 1:
The connection structure is divided into modular components: support elements, connection elements, and electrical connection tabs. Each component has a specific function and can be manufactured separately, then assembled through laser welding. This segmentation simplifies manufacturing while maintaining connection reliability.
Solution Approach 2:
The support element and connection element are combined into an integrated structure that provides both mechanical support and electrical connection functions. This merging reduces the number of separate components and simplifies the manufacturing process while ensuring reliable electrical connection between electrodes and terminals.
2Strength
If traditional connection structures are used, then adequate mechanical strength can be achieved, but the overall assembly size increases
Solution Approach 1:
The connection elements and support elements are arranged in a nested configuration where components are positioned within the available space of the battery assembly. The connection ribs are integrated within the support structure, maximizing space utilization and reducing overall assembly volume while maintaining adequate connection strength.
Solution Approach 2:
The connection structure utilizes three-dimensional spatial arrangement with connection elements extending in multiple directions. The support elements are positioned at strategic locations to provide strength while minimizing volume occupation. This dimensional optimization allows strong connections within a compact footprint.
3Manufacturing precision
If laser welding is used to fasten connection elements, then manufacturing precision and speed are improved, but deformation during welding may occur
Solution Approach 1:
The support elements and connection elements are pre-positioned and fixed in their correct locations before the laser welding process begins. This preliminary positioning ensures that during welding, the components remain stable and do not deform, while still achieving precise connections. The tabs are also pre-formed with appropriate geometry to facilitate accurate welding.
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 configuration enables a cost-effective and efficient manufacturing process with a compact design, ensuring robust electrical connections and reducing the risk of deformation during welding.
Implementation Method 1
The first common connection element is fastened to the first electrical connection tab by a material connection, in particular by laser welding
Data Source
AI summary
An electrochemical assembly includes a first stack of electrochemical elements provided with a first electrical connection tab with a first polarity. The first stack of electrochemical elements extends along a stacking plane. A first common connection element is adapted to electrically connect the first electrical connection tab to an electrical connection terminal with the first polarity.