Battery Terminal Welding Track for Current Flow and Low Spatter
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Solution Overview
Problem
Insufficient current flow and excessive weld spatter at the electrical connection between the connecting sheet and the terminal post of a secondary battery lead to disconnection, temperature rise, and increased internal resistance, posing safety issues.
Innovation Solution
The secondary battery design includes a connecting sheet and terminal post with a welding surface, where the effective fusion width, area, and length of the welding track satisfy the relationship 2≤S/(A*L)≤20000, ensuring sufficient current flow and minimizing weld spatter to enhance safety performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding area between the connecting sheet and terminal post is increased to improve current flow, then the current flow is improved, but the weld spatter increases and internal resistance increases
Solution Approach 1:
The patent applies local quality by creating a welding structure where the welding part penetrates through the connecting sheet to form a welding track on the terminal post surface. This localized penetration welding concentrates the fusion in specific areas (effective fusion width A and length L) rather than spreading heat across a large area, thereby improving current flow through the welding part while minimizing weld spatter and internal resistance increase.
2Strength
If the welding area is increased to prevent disconnection, then connection strength is improved, but temperature rise during welding increases
Solution Approach 1:
The patent segments the welding process into two distinct zones: (1) a penetration welding zone where the welding part extends through the connecting sheet into the terminal post with effective fusion width A and length L, creating strong mechanical interlocking; and (2) a surface welding zone with controlled heat input that forms a welding track without excessive melting. This segmentation allows achieving strong connection (peeling force 248-973 N) while controlling overall welding temperature and minimizing heat-affected zone.
3Reliability
If penetration welding is used to improve connection reliability, then disconnection is prevented, but manufacturing precision requirements increase
Solution Approach 1:
The patent defines specific parameter ranges to balance penetration welding effectiveness with manufacturing feasibility: effective fusion width A (0.1-3 mm), effective fusion length L (1-200 mm), and the ratio S/(A*L) between 2-20000. These parameter specifications provide clear manufacturing targets that ensure reliable penetration welding (peeling force 248-973 N) while accommodating normal manufacturing tolerances. The ratio parameter S/(A*L) particularly helps control welding quality without requiring extreme precision.
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 design guarantees a sufficient current flow area while reducing weld spatter, preventing disconnection and temperature rise, thus improving the safety and connection strength of the battery.
Implementation Method 1
the connecting sheet is fixed to the terminal post by welding, forming a welding part
Data Source
AI summary
A secondary battery is disclosed, which includes a connecting sheet and a terminal post; the connecting sheet has a welding surface; the terminal post and the connecting sheet are stacked, and the welding surface faces the terminal post; the connecting sheet is fixed to the terminal post by welding, forming a welding part; part of the welding part is provided in an interior of the connecting sheet and part of the welding part is provided in an interior of the terminal post; the welding part penetrates through the welding surface, and forms a welding track on the welding surface.