Secondary Battery Tab-to-Lead Bonding for Simpler Assembly
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Solution Overview
Problem
The manufacturing process of secondary batteries, particularly those with multiple electrode bodies and current-collecting tabs, is complicated due to the complexity of joining current-collecting tabs to leads using methods like laser welding or ultrasonic bonding.
Innovation Solution
The implementation of a secondary battery design where current-collecting tab groups are divided into multiple tab groups, each bonded to both sides of a common lead using ultrasonic bonding, simplifying the bonding process and increasing the bonding area for improved thermal conductivity and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current-collecting tabs are joined to leads using laser welding or ultrasonic bonding, then electrical connection is achieved, but the manufacturing process becomes complicated
Solution Approach 1:
The current-collecting tabs are divided into multiple tab groups, with each group bonded to a corresponding bonding portion of the lead. This segmentation allows for simplified bonding operations compared to joining all tabs individually to a single lead point, reducing manufacturing complexity while maintaining reliable electrical connection.
2Reliability
If multiple current-collecting tabs are joined to a single lead, then electrical connection is established, but the bonding area is limited
Solution Approach 1:
The lead is designed with multiple bonding portions extending in different directions, allowing current-collecting tab groups to be bonded at multiple locations along the lead's length. This dimensional expansion of the bonding interface significantly increases the total bonding area while maintaining reliable electrical connection across all tabs.
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 simplifies the bonding process, enhances current draw capabilities, and improves the vibration resistance of current collector tabs, while maintaining high energy density and manufacturing efficiency.
Implementation Method 1
each bonded to both sides of a common lead using ultrasonic bonding
Data Source
AI summary
According to one embodiment, a secondary battery includes an outer container with a lid, an electrode body stored in the outer container and including an electrode group, a positive electrode current collecting tab group and a negative electrode current collecting tab group, output terminals on the lid, a positive electrode lead, and a negative electrode lead. A second joint portion of the electrode leads has a first joint surface and a second joint surface opposing each other. A part of current collector tab groups of the same polarity is joined to the first joint surface, and another part of the group of current collector tabs of the same polarity is joined to the second joint surface and opposing the part of the current collector tab groups across the second joint portion.