Battery Tab Connecting Piece to Prevent Welding Wrinkles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In battery manufacturing, the need for longer tabs to facilitate welding leads to wrinkles and reduces yield, complicating the assembly process.
Innovation Solution
A battery design featuring a first connecting piece with segments that extend from the cell tabs to the battery case, allowing for stable and efficient electrical connections without excessive tab length, thereby improving assembly efficiency and reducing the risk of wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tab is made longer to enable welding to another cover plate terminal, then the welding possibility is improved, but wrinkles occur and yield is reduced
Solution Approach 1:
The connecting piece is divided into multiple segments (first segment, second segment, third segment) that can be independently configured. This segmentation allows the connecting structure to achieve welding connectivity without requiring excessive tab length, thereby preventing wrinkles while maintaining manufacturing feasibility.
Solution Approach 2:
A separate connecting piece is introduced as an intermediary component between the tab and the cover plate terminal. This mediator enables welding connectivity without extending the tab itself, thus avoiding the wrinkle problem while achieving the desired electrical and mechanical connection.
2Reliability
If the tab is made longer to facilitate welding, then the electrical connection is improved, but the assembly process becomes more complex
Solution Approach 1:
The connecting structure is segmented into multiple functional parts (first segment for tab connection, second segment for positioning, third segment for terminal connection). This segmentation allows each part to perform its specific function efficiently, ensuring reliable electrical connection while keeping the overall assembly process manageable through modular construction.
Solution Approach 2:
The connecting piece is pre-formed with specific segments and configurations before assembly. This preliminary preparation allows for easier and more reliable electrical connection during the actual assembly process, reducing complexity by having components ready in their final configurations rather than requiring complex in-situ forming operations.
3Ease of operation
If the tab length is increased to reach another cover plate terminal, then the connectivity is improved, but the structural integrity deteriorates
Solution Approach 1:
The connecting piece is divided into segments where the first segment connects to the tab, the second segment provides structural support and positioning, and the third segment connects to the terminal. This segmentation distributes mechanical loads across multiple points, maintaining structural integrity while achieving the necessary connectivity without excessive tab length.
Solution Approach 2:
The connecting piece serves as a mediator that provides structural support between the tab and the cover plate terminal. This intermediary component maintains structural integrity by distributing forces and providing rigid support, eliminating the need to extend the tab itself which would compromise its structural strength.
Data Source
AI summary
A battery includes a battery case, a cell, and a first connecting piece. The cell is disposed in the battery case and includes a cell main body, and first and second tabs extending from opposite ends of the cell main body to be respectively connected to opposite sides of the battery case. The first connecting piece includes first, second and third segments. Two ends of the first segment are connected to the second and third segments, respectively. The second and third segments are connected to the second tab and the battery case, respectively. The first segment is located between the second and third segments, the second segment is bent on a first side of the first segment, the third segment is bent on a second side of the first segment, and the first and second sides are located on opposite sides.