Busbar Tab Indentation and Rolling for Foil-Safe Welding
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Solution Overview
Problem
Existing busbar manufacturing processes face challenges with upwardly extending tabs that interfere with battery cell foils, leading to tearing and failure, especially in limited packaging spaces and during welding processes.
Innovation Solution
A method involving indenting tabs to form separate portions, compressing and bending them about an indentation to secure them to the busbar, and using a roller assembly and welding device to ensure uniform contact and secure bonding, reducing elastic forces and preventing foil damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are extended upward from the busbar for electrical connection, then electrical connection capability is improved, but packaging space is reduced and risk of foil tearing increases
Solution Approach 1:
The tab is segmented into multiple portions (first tab portion and second tab portion) separated by an indentation. This segmentation allows the tab to be compressed and bent to fit within limited packaging space while maintaining electrical connection capability through the busbar opening.
Solution Approach 2:
The tab is bent from an upward extending configuration to a horizontal configuration along the busbar surface. This dimensional change allows the tab to maintain electrical connection functionality while occupying significantly less vertical packaging space.
2Reliability
If tabs are extended upward from the busbar, then electrical connection is facilitated, but risk of foil tearing and battery cell failure increases
Solution Approach 1:
The tab is pre-compressed and bent to a horizontal position before the welding process. This preliminary action ensures the tab is already in the correct position and reduces elastic forces during welding, preventing foil tearing that would occur if the tab were forced into position during welding.
Solution Approach 2:
The compression and bending process applies force to the tab in advance to counteract the elastic forces that would otherwise cause the tab to move or deform during welding. This preliminary anti-action prevents the harmful effect of foil tearing.
3Volume of moving object
If tabs are compressed and bent during manufacturing, then packaging space utilization is improved, but manufacturing process complexity increases
Solution Approach 1:
The compression, bending, and welding operations are merged into a single integrated manufacturing process. The press applies compression force that simultaneously creates the indentation, bends the tab to the desired angle, and positions it for welding, eliminating the need for separate operations.
Solution Approach 2:
The press device performs multiple functions: it compresses the tab, creates the indentation, bends the tab to the correct angle, and positions it for welding. This multi-functional approach reduces overall manufacturing complexity despite the increased sophistication of the individual press device.
4Manufacturing precision
If tabs are bent over during welding, then contact with busbar is improved, but process variation increases and welding consistency deteriorates
Solution Approach 1:
The tab is pre-bent to the exact welding position during the compression process, eliminating the need for bending during welding. This preliminary positioning ensures consistent contact and eliminates process variation that would occur if bending were performed during the welding operation itself.
Solution Approach 2:
The manual or mechanical bending process during welding is replaced with a controlled compression and bending process performed beforehand by the press. This substitution provides more precise control over the tab position and reduces variability in the welding process.
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 enhances the reliability of busbar connections by preventing foil tears and ensuring consistent welding, improving battery durability and reducing packaging issues.
Implementation Method 1
the indentation reduces elastic forces of the metal sheet resulting in the tab moving back towards an original position
Implementation Method 2
a roller assembly including a rolling element that may compress a first tab portion of the tab that extends from the indentation against a busbar
Implementation Method 3
a welding device that may weld the first tab portion of the tab to the busbar
Data Source
AI summary
An assembly that may include a press that may form an indentation within a tab, a roller assembly including a rolling element that may compress a first tab portion of the tab that extends from the indentation against a busbar, and a welding device that may weld the first tab portion of the tab to the busbar.