Battery Tab Welding via Segmented Energy Beam Control
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Solution Overview
Problem
The challenge lies in producing high-quality batteries with multiple current collecting tabs welded to an outer case using an energy beam, where achieving sufficient weld strength while preventing sputter and controlling the energy beam output is difficult, especially when using two or more current collecting tabs, due to variations in thickness and the need for high-power equipment, leading to increased costs.
Innovation Solution
A battery design where multiple current collecting tabs are welded to an outer case using a weld group with a first weld extending to all tabs and a second weld to only some, utilizing a first and second energy beam with different energy amounts to ensure sufficient weld strength and reduce equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the output of the energy beam is increased to weld multiple current collecting tabs to the outer case, then sufficient weld strength is achieved, but the melted part penetrates the current collecting tab to cause sputter inside the battery
Solution Approach 1:
The welding process is divided into two distinct stages: a first welding step that welds the outer case to all multiple current collecting tabs, and a second welding step that welds the outer case to only one or some of the current collecting tabs. This segmentation allows each welding step to use appropriate energy levels, preventing penetration and sputter while achieving sufficient overall weld strength through the combined effect of both welds.
2Strength
If two or more current collecting tabs are welded to the outer case via one weld, then the joint area is increased to produce sufficient weld strength, but the output of the energy beam needs to be very high, making it difficult to secure the margin of the output
Solution Approach 1:
The welding process is divided into two distinct stages: a first welding step that welds the outer case to all multiple current collecting tabs, and a second welding step that welds the outer case to only one or some of the current collecting tabs. This segmentation allows each welding step to use appropriate energy levels, preventing penetration and sputter while achieving sufficient overall weld strength through the combined effect of both welds.
3Strength
If the output of the energy beam is increased to weld multiple current collecting tabs, then sufficient weld strength is achieved, but high-power equipment is required, resulting in increased equipment cost
Solution Approach 1:
The welding process is divided into two distinct stages: a first welding step that welds the outer case to all multiple current collecting tabs, and a second welding step that welds the outer case to only one or some of the current collecting tabs. This segmentation allows each welding step to use appropriate energy levels, preventing penetration and sputter while achieving sufficient overall weld strength through the combined effect of both welds.
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 reduces the energy beam output required for welding, providing a sufficient margin and lowering equipment costs, enabling the production of high-quality batteries at a lower cost while maintaining reliable weld strength.
Implementation Method 1
an energy beam, such as laser beam, is emitted from the outside of an outer case to weld the outer case to a current collecting tab
Implementation Method 2
When the output of an energy beam, such as a laser beam, emitted from the outside of the outer case is too high, the melted part penetrates the current collecting tab
Data Source
AI summary
A battery producible with high quality and at low costs by decreasing the output of an energy beam used to weld multiple current collecting tabs to an outer case and thus securing the sufficient margin of the output thereof. An aspect of the battery includes an overlapping part K of multiple current collecting tabs connected to a negative electrode of an electrode body being welded to an outer case via a weld group, and the weld group includes a weld part and weld part that are each in the form of a line when they are viewed from the outside of the outer case. The weld as a first weld serves to weld the outer case to all of the multiple current collecting tabs, and the weld as a second weld serves to weld the outer case to only one or some of the multiple current collecting tabs.