Secondary Battery Tab Assembly With Straight-Through Welded Tabs
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Solution Overview
Problem
The existing secondary battery assembly structures face issues such as low space utilization, safety risks due to tab bending, and high material costs, along with inadequate adhesive tape safety performance, which affect energy density, performance, and production efficiency.
Innovation Solution
The proposed secondary battery assembly includes an electric cell assembly with tabs that pass through specific holes and assembly parts on an insulation plate and transfer conductor, allowing for welding without bending, and a self-matched shell with a limited structure to reduce external force requirements, along with a double-sided protective adhesive layer for improved safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tab is bent during assembly to connect with the top cover, then the connection is achieved, but the space utilization rate in the height direction decreases and energy density improvement becomes difficult
Solution Approach 1:
Instead of bending the tab to achieve connection, the patent inverts the approach by keeping the tab straight and horizontal, and instead bending or folding the top cover to connect with the tab. This eliminates the need for tab bending, improves space utilization in the height direction, and enables energy density improvement while maintaining reliable electrical connection.
2Ease of manufacture
If the tab is bent with limited space, then the assembly is completed, but the tab becomes redundant and sinking causing short circuit safety risks
Solution Approach 1:
The patent inverts the bending operation from the tab to the top cover. The tab remains straight and horizontal without sinking or becoming redundant, while the top cover is folded or bent to achieve the necessary connection geometry. This eliminates the safety risk of tab short circuits while completing the assembly.
3Ease of manufacture
If the tab is bent without support, then the assembly proceeds, but the tab may insert into the electrode sheet causing short circuit safety risks
Solution Approach 1:
Instead of bending the unsupported tab which risks insertion into the electrode sheet, the patent keeps the tab straight and horizontal with proper support, and instead folds or bends the top cover to achieve connection. This eliminates the safety risk of tab insertion while maintaining assembly processability.
4Reliability
If the tab is bent and squeezed during assembly, then the connection is achieved, but the tab is stressed and easy to be damaged or broken affecting performance and service life
Solution Approach 1:
The patent inverts the deformation from the tab to the top cover. The tab remains straight and undamaged with full strength, while the top cover absorbs the deformation through folding or bending. This eliminates tab damage and stress concentration, ensuring long-term performance and service life.
5Reliability
If the tab is made long to reach the top cover, then the connection is achieved, but the internal resistance of the battery increases affecting performance
Solution Approach 1:
Instead of making the tab long to reach the top cover, the patent keeps the tab short and horizontal, and instead folds or bends the top cover to connect with the tab. This minimizes the tab length and reduces internal resistance while maintaining reliable electrical connection.
6Ease of manufacture
If external force is used to press the transfer sheet and insulation plate during assembly, then the assembly is completed, but the production efficiency decreases and cost increases
Solution Approach 1:
The patent applies self-service principle by designing the shell with a limited structure that automatically limits and guides the assembly process. The shell structure itself provides the necessary constraint and positioning, eliminating the need for external pressing forces during assembly. This improves production efficiency while ensuring complete assembly.
Data Source
AI summary
A secondary battery comprises a secondary battery assembly, the secondary battery assembly comprises an electric cell assembly, a transfer conductor and an insulation plate, wherein the electric cell assembly comprises at least two electric cells arranged side by side, and each electric cell has a tab extending from the top surface of the electric cell. The transfer conductor is provided with a transfer conductor tab assembly part. The insulation plate is located between the electric cell assembly and the transfer conductor, and the insulation plate is provided with a plate tab matching part, wherein, the folded tab passes through the plate tab matching part of the base plate and the transfer conductor tab assembly part in turn, and then is welded with the transfer conductor. The secondary battery of the application features short tabs, good battery performance, high safety, high assembly efficiency and low cost.