Battery Tab Segmentation for Heterogeneous Metal Welding
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Solution Overview
Problem
The joining of heterogeneous metal tabs in batteries, such as aluminum and copper, poses challenges due to their different physical properties, leading to reduced weldability, durability, and increased contact resistance, with existing methods failing to address these issues effectively.
Innovation Solution
The battery design involves forming tabs with distinct welding and reaction regions made of the same material, allowing for improved weldability by ensuring that at least one of the anode or cathode tabs has a welding region and a reaction region formed of the same material, with the option to use a sealant at their interface to enhance joining intensity and sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heterogeneous metals (aluminum and copper) are used for cathode and anode tabs respectively, then electrochemical stability and reactivity are improved, but weldability deteriorates due to different physical properties
Solution Approach 1:
The tab is divided into two distinct regions: a reaction region made of heterogeneous metals (aluminum for cathode, copper for anode) to ensure electrochemical stability, and a welding region made of homogeneous metal to ensure weldability. This segmentation allows each region to be optimized for its specific function without compromise.
Solution Approach 2:
Different parts of the tab are assigned different material properties: the reaction region uses heterogeneous metals optimized for electrochemical performance, while the welding region uses homogeneous metal optimized for joining. This local differentiation resolves the contradiction between electrochemical stability and weldability.
2Reliability
If heterogeneous metals are joined together, then electrochemical performance is maintained, but joining intensity and durability are reduced
Solution Approach 1:
The tab structure is segmented into a reaction region with heterogeneous metals for electrochemical performance and a welding region with homogeneous metal for strong joining. The segmentation ensures that the weak joining of heterogeneous metals does not affect the overall durability.
Solution Approach 2:
The homogeneous welding region acts as an intermediary that connects to both heterogeneous metal tabs through welding, providing a strong mechanical and electrical connection while allowing the heterogeneous reaction regions to maintain their electrochemical functions.
3Ease of manufacture
If heterogeneous metals are welded, then tab connection is achieved, but contact resistance increases due to different physical properties
Solution Approach 1:
The tab is segmented so that welding occurs only in the homogeneous welding region, ensuring low contact resistance at the connection point, while the heterogeneous reaction regions remain separate for electrochemical function. This segmentation prevents high contact resistance in the welding joint.
4Reliability
If different materials are used for cathode and anode tabs, then electrochemical reactivity is improved, but uniform welding intensity cannot be achieved
Solution Approach 1:
The tab design applies local quality by making the welding region homogeneous while allowing the reaction region to be heterogeneous. This ensures uniform welding intensity in the welding region while maintaining optimal electrochemical reactivity in the reaction region.
Solution Approach 2:
The tab is segmented into welding and reaction regions with different material compositions. This segmentation allows the welding region to achieve uniform welding intensity through homogeneous material properties, while the reaction region maintains high electrochemical reactivity through heterogeneous metal composition.
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 significantly enhances weldability, increases durability, reduces contact resistance, and maintains uniform weld quality, thereby preventing performance deviations in battery products.
Implementation Method 1
Various methods such as ultrasonic welding, laser welding, resistance welding, and so on may be used for welding for cell tab connection
Data Source
AI summary
A battery comprises: a battery cell; and tabs configured as one pair of an anode tab and a cathode tab and included in the battery cell. At least one of the anode tab and the cathode tab is configured in such a way that a welding region exposed outside the battery cell and a reaction region positioned in the battery cell are formed of different metals and are joined to each other.