Battery Terminal Base Plate Welding Without a Connecting Plate
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Solution Overview
Problem
Conventional battery manufacturing processes are complex and costly due to the need for multiple welding steps, including the use of connecting plates, which increases the weight of the cell structural member and reduces energy density.
Innovation Solution
A battery design where the tab is directly welded to a base plate within the terminal, eliminating the need for a connecting plate and simplifying the manufacturing process by integrating the base plate as part of the terminal, allowing for ultrasonic and laser welding techniques to form the tab and terminal connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a connecting plate is used to connect the tab to the terminal, then the structural strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The base plate is integrated as an integral part of the terminal structure, eliminating the need for a separate connecting plate. The terminal body and base plate form a unified component that directly connects to the tab, reducing the number of parts and assembly steps while maintaining structural integrity.
Solution Approach 2:
The base plate serves multiple functions: it provides structural support, acts as a mounting surface for the terminal, and serves as the direct connection point for the tab. This multi-functional design replaces the need for separate connecting plates while maintaining all necessary mechanical and electrical functions.
2Reliability
If multiple welding steps are used to connect the tab to the terminal via connecting plate, then the connection reliability is improved, but the manufacturing time and cost increase
Solution Approach 1:
The base plate and terminal body are designed as an integral structure, allowing the tab to be welded directly to the terminal in a single operation. This eliminates the multiple welding steps previously required to connect the tab to the connecting plate and then to the terminal, reducing manufacturing time and cost while maintaining connection reliability.
Solution Approach 2:
The base plate is pre-configured with the terminal body as an integral structure before the tab welding process. This preliminary integration of components allows for a simplified welding operation that achieves reliable connection in fewer steps, improving manufacturing efficiency without compromising connection strength.
3Manufacturing precision
If the base plate size is increased to improve welding performance, then the welding quality is improved, but the weight of the cell structural member increases
Solution Approach 1:
The base plate is designed with optimized local dimensions that provide sufficient welding area and structural support only where needed. The size and shape of the base plate are specifically tailored to accommodate the tab welding process and provide adequate heat dissipation and mechanical strength, without unnecessarily increasing the overall weight of the cell structural member.
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 manufacturing complexity and costs, increases energy density, and optimizes the size of the base plate for improved welding performance, especially for cells with a wide-to-length ratio greater than 1:4, while minimizing thermal influence on sealing components.
Implementation Method 1
The electrode leads form the tab through ultrasonic welding
Implementation Method 2
the tab is laser welded to the base plate
Data Source
AI summary
A battery is provided. The battery includes a cell, including a tab; a casing, including an opening, wherein the cell is accommodated in the casing; a cover plate assembly, covering the opening; and a terminal, fixed onto the cover plate assembly and including a terminal body penetrating the cover plate assembly and a base plate disposed on a back surface of the cover plate assembly. The tab is welded to the base plate.