Prismatic Battery Tab-to-Terminal Welding for Higher Energy Density
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Solution Overview
Problem
Existing secondary batteries, particularly prismatic-housing batteries, are limited by the thickness of connecting pieces used to connect the electrode assembly to the top cover, which restricts energy density and increases manufacturing costs.
Innovation Solution
Directly connecting the electrode assembly tabs to the terminal post of the top cover assembly using ultrasonic or torque welding, eliminating the need for connecting pieces, thereby optimizing the use of inner space and reducing manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If connecting pieces are used to connect the electrode assembly to the top cover, then the structural stability is improved, but the energy density deteriorates due to increased thickness and reduced inner space
Solution Approach 1:
The patent removes the connecting pieces from the battery structure, directly connecting the electrode assembly tabs to the terminal post. This extraction eliminates the thickness occupation and weight of connecting pieces, thereby increasing the inner space available for electrode assembly and improving energy density while maintaining structural stability through direct welding connections.
Solution Approach 2:
The patent merges the function of connecting pieces with the terminal post structure itself. The terminal post is designed to directly receive and weld the electrode assembly tabs, combining the support and connection functions into a single integrated component, thus eliminating the need for separate connecting pieces and maximizing space utilization.
2Strength
If connecting pieces are used to connect the electrode assembly to the top cover, then the mechanical connection is improved, but the manufacturing cost deteriorates due to additional materials and welding processes
Solution Approach 1:
The patent eliminates connecting pieces from the manufacturing process, removing the associated material costs and welding operations. The electrode assembly tabs are directly welded to the terminal post in a single step, reducing both material expenses and manufacturing complexity while maintaining adequate mechanical connection strength.
Solution Approach 2:
The terminal post is designed to serve multiple functions: providing electrical connection, mechanical support, and direct welding surface for electrode assembly tabs. This multi-functionality eliminates the need for separate connecting pieces, reducing both material costs and manufacturing steps while ensuring robust mechanical and electrical connections.
3Reliability
If connecting pieces are used, then the connection reliability is improved, but the battery weight increases due to additional materials
Solution Approach 1:
The patent removes connecting pieces from the battery structure, eliminating their weight contribution. The direct welding of electrode assembly tabs to the terminal post maintains connection reliability through proper welding design and process control, achieving the same functional reliability without the additional weight of intermediate components.
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
Improves energy density by maximizing the inner space of the battery housing and reduces manufacturing costs by omitting the use of connecting pieces and associated welding processes.
Implementation Method 1
the first tab is directly connected to the bottom plate through ultrasonic welding
Implementation Method 2
the first tab is directly connected to the bottom plate through torque welding
Data Source
AI summary
A secondary battery including an electrode assembly and a top cover assembly is provided. The electrode assembly has a first tab. The top cover assembly includes a top cover plate and a terminal post. The terminal post includes a bottom plate disposed on a side of the top cover plate facing the electrode assembly, wherein the first tab is directly connected to the bottom plate.