Battery Tab Welding Layout for Cap-Safe Current Collection
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Solution Overview
Problem
Existing secondary battery manufacturing processes face challenges in efficiently connecting electrode tabs to current collecting plates, particularly in ensuring reliable electrical connections and preventing damage to the cap assembly during welding, while maintaining a compact design.
Innovation Solution
The solution involves bending electrode tabs in multiple directions to align with current collecting plates, using insulating members to prevent short circuits, and employing a specific welding pattern with reduced welding output at notches to secure connections without damaging the cap assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode tabs are connected to current collecting plate using conventional welding methods, then electrical connection is established, but the cap assembly may be damaged during welding process
Solution Approach 1:
The current collecting plate is bent in advance to a predetermined shape before welding, with the welding portion positioned away from the cap assembly. This preliminary positioning ensures that during welding, the heat-affected zone does not reach the cap assembly, preventing damage while maintaining reliable electrical connection.
Solution Approach 2:
The welding portion of the current collecting plate is specifically positioned at a location with different thermal characteristics - away from the cap assembly. This local positioning allows concentrated welding heat without affecting the cap assembly, resolving the contradiction between achieving reliable welding and preventing cap damage.
2Adaptability or versatility
If current collecting plate is extended to accommodate multiple electrode tabs, then connection capacity increases, but manufacturing complexity increases
Solution Approach 1:
The current collecting plate is bent into a curved configuration with specific radii of curvature. This curvature allows the plate to accommodate multiple electrode tabs in a compact arrangement while maintaining uniform welding characteristics throughout, achieving high connection capacity without proportionally increasing manufacturing complexity.
Solution Approach 2:
The current collecting plate is divided into distinct functional portions: a welding portion for connecting electrode tabs, a bent portion for spatial arrangement, and a terminal portion for external connection. This segmentation allows each portion to be optimized independently, increasing overall adaptability while keeping the manufacturing process manageable.
3Reliability
If electrode tabs are bent in multiple directions to align with current collecting plate, then connection reliability improves, but manufacturing precision requirements increase
Solution Approach 1:
The electrode tabs are bent in advance to predetermined angles and directions before the welding process. This preliminary bending ensures proper alignment with the current collecting plate's welding portion, achieving reliable electrical connection while allowing for standard manufacturing tolerances through pre-positioning.
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 method ensures robust electrical connections between electrode tabs and current collecting plates, prevents damage to the cap assembly, and allows for a more compact and efficient battery design by extending the current collecting plate's length without additional processes.
Implementation Method 1
employing a specific welding pattern with reduced welding output at notches to secure connections without damaging the cap assembly
Implementation Method 2
connecting the plurality of stacked electrode tabs and the current collecting plate
Data Source
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AI summary
A secondary battery includes an electrode assembly, the electrode assembly including a plurality of stacked electrode tabs, a case with an open side, the case accommodating the electrode assembly therein, a cap assembly sealing the open side of the case, the cap assembly comprising an electrode hole, and a current collecting plate connected to the plurality of stacked electrode tabs, the current collecting plate being inserted into and passing through the electrode hole.