Battery Cell Tab Connection via Mechanical Pressing
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Solution Overview
Problem
Existing methods for connecting tabs in flexible lithium ion battery packs, such as tin soldering, laser welding, and ultrasonic welding, face issues like high temperature damage, irreversible connections, and space constraints, making it difficult to assemble and maintain the battery packs effectively.
Innovation Solution
A device using an isolation board, metal plate, and metal conductive board with ribs and grooves, secured by screws and hooks, allows for detachable and stable connection of battery cell tabs, enabling easy assembly and disassembly without soldering materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tin soldering is used to connect tabs, then connection stability is improved, but high temperature is generated causing damage to battery cells
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical pressing connection system. A pressing device applies mechanical force to press the tabs of battery cells together with a pressing plate, creating a stable electrical connection without generating high temperature. This substitution eliminates the harmful thermal effects while maintaining connection reliability through mechanical contact force.
2Strength
If laser welding or ultrasonic welding is used to connect tabs, then connection strength is improved, but the welding becomes irreversible preventing cell replacement
Solution Approach 1:
The patent employs a dynamic pressing connection system where the pressing device can apply and release mechanical force as needed. The tabs are pressed together with sufficient force to ensure strong electrical connection during operation, but the pressing force can be released to allow disassembly and replacement of battery cells. This dynamic mechanical connection provides both strength during use and flexibility for maintenance.
3Reliability
If laser welding or ultrasonic welding is used to connect tabs, then connection reliability is improved, but adequate space is required affecting small thickness batteries
Solution Approach 1:
The patent extracts the complex welding equipment and process from the battery assembly system, replacing it with a simple mechanical pressing device. The pressing device consists of basic components (pressing plate, pressing mechanism) that require minimal space and can be easily integrated into compact battery structures. This extraction eliminates the need for large welding equipment while maintaining connection reliability through direct mechanical contact.
Data Source
AI summary
A device for connecting tabs of battery cells includes an isolation board defining a first through slot seated on the surfaces of the battery cells from which the tabs extending out; a metal plate mounted on a surface of the isolation board afar from the battery cells, the metal plate defining a second through slot corresponding to the first through slot of the isolation board; and a metal conductive plate secured to the metal plate. The tabs of the battery cells extending through the first through slot and the second through slot are bent and seated on a surface of the metal plate afar from the isolation board, and the metal conductive plate is detachably fastened to the metal plate so that the tabs of the battery cells are securely sandwiched between the metal plate and the metal conductive plate.