Battery Cell Tab Lead Segmentation for Lower-Risk Welding

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Solution Overview

Problem

Existing battery cells face challenges in enhancing current conveyance capacity while minimizing the risk of electrode tab cracking, cold joints, and safety hazards due to high welding power and pressure requirements.

Innovation Solution

The battery cell design incorporates a plurality of connection portions on the electrode lead member, reducing the layer amount of electrode tabs per connection, and employs a separator assembly to separate welding portions, using materials with high thermal conductivity, melting point, and tensile strength to improve connection strength and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple electrode tabs are welded to a single connection portion, then current conveyance capacity is improved, but welding difficulty increases and connection strength decreases

Engineering Contradiction:

Improveconnection strengthVSAvoidwelding difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The electrode lead member is divided into multiple connection portions (first connection portion, second connection portion, etc.), each welding to a corresponding electrode tab set. This segmentation distributes the welding load, reducing the number of tabs per weld point and improving both connection strength and welding ease.

Inventive Principle:

Principle #1Segmentation

2Strength

If high welding power is applied to weld multiple electrode tabs, then connection strength is improved, but electrode tab cracking and cold joints increase

Engineering Contradiction:

Improveconnection strengthVSAvoidelectrode tab cracking

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

By segmenting the welding points into multiple connection portions, each welding operation involves fewer electrode tabs, allowing lower welding power to be used while still achieving adequate connection strength, thereby reducing the risk of cracking and cold joints.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The welding parameters (power, duration) are optimized for each individual welding point involving fewer tabs, rather than attempting to weld multiple tabs simultaneously with high power. This parameter adjustment prevents harmful thermal effects while maintaining connection quality.

Inventive Principle:

Principle #35Parameter changes

3Strength

If high welding power and pressure are used to weld electrode tabs, then connection strength is improved, but safety hazards increase

Engineering Contradiction:

Improveconnection strengthVSAvoidsafety hazards

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Multiple connection portions distribute the welding operations, reducing the cumulative thermal and mechanical stress on any single point and on the electrode tabs overall, thereby improving safety while maintaining connection strength.

Inventive Principle:

Principle #1Segmentation

4Strength

If long welding duration is used to weld multiple electrode tabs, then connection strength is improved, but productivity decreases

Engineering Contradiction:

Improveconnection strengthVSAvoidwelding efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

By dividing the welding tasks into multiple shorter welding operations at different connection portions, the total welding time can be reduced through parallel processing or more efficient sequential operations, improving productivity while maintaining adequate connection strength.

Inventive Principle:

Principle #1Segmentation

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 reduces welding difficulty, enhances connection strength, minimizes cracking and cold joints, and improves safety performance by reducing welding power and duration, thereby increasing current conveyance capacity and extending cycle life.

Implementation Method 1

welding power and shortening welding duration

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

each of the connection portions is welded to at least one of the electrode tab sets

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20250219264A1Battery cell, battery, electric device and welding apparatus

Publication Date: 2025.07.03 JIANGSU CONTEMPORARY AMPEREX TECH LTD

AI summary

A battery cell, a battery, an electric device and a welding apparatus are disclosed. The battery cell includes a housing, an electrode unit and an electrode lead member. The electrode unit is accommodated in the housing and includes a plurality of electrode tab sets arranged in a stacked way, and each of the electrode tab sets includes at least one electrode tab. The electrode lead member is arranged at the housing and includes a plurality of connection portions, each of the connection portions is welded to at least one of the electrode tab sets, and a plurality of electrode tab sets welded to the plurality of connection portions of the electrode lead member have a same polarity. By providing a plurality of connection portions on the electrode lead member, a layer amount of the electrode tabs welded to a single connection portion can be reduced.