Welding Metal Tab to Cable Battery Electrode Current Collector
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Solution Overview
Problem
Conventional welding methods for metal tabs to electrode layers in cable-type secondary batteries result in poor weld quality due to the insulating and conductive polymer layers, limiting the improvement of weld performance.
Innovation Solution
A method involving the removal of a portion of the conductive layer using a pulse laser to expose the current collector surface, allowing for the successful welding of a metal tab to the current collector, which is then welded using a pulse laser or ultrasonic waves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods are used on the electrode layer with polymer layers, then the welding process can be performed, but the weld quality becomes poor
Solution Approach 1:
The conductive layer is removed in advance using a pulse laser before the welding process. This preliminary action exposes the current collector surface, creating optimal conditions for subsequent welding by eliminating the polymer layer interference that would otherwise prevent good weld quality
Solution Approach 2:
The conductive layer (polymer material) is extracted or removed from the electrode layer surface at the welding location. This extraction eliminates the harmful insulating barrier between the welding tool and the current collector, enabling reliable welding while preserving the conductive layer in other areas where it provides necessary functionality
2Reliability
If the conductive layer is removed to improve weld quality, then welding performance increases, but the electrode structure becomes more complex
Solution Approach 1:
The conductive layer is selectively removed only at the specific welding location on the electrode layer, while the rest of the electrode maintains its original structure with the conductive layer intact. This localized modification improves weld performance without requiring complex changes to the overall electrode structure
Solution Approach 2:
A pulse laser is used to remove the conductive layer instead of mechanical methods. This substitution provides precise, controlled removal with minimal structural disturbance, achieving clean exposure of the current collector while maintaining simplicity in the electrode structure
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
Enables high-quality welding of metal tabs to electrode layers, overcoming the limitations of conventional techniques and achieving reliable connections in cable-type secondary batteries.
Implementation Method 1
removing a portion of the conductive layer using a pulse laser, thus exposing the surface of the current collector positioned thereunder
Implementation Method 2
welding a metal tab to the surface of the current collector
Implementation Method 3
welding a metal tab to the surface of the current collector
Data Source
Figure 1
Figure 2~3
Figure 4(A)~4(C)
AI summary
Disclosed are a method of welding a metal tab of an electrode layer for a cable battery and an electrode manufactured thereby. This welding method, suitable for welding a metal tab to an electrode including a current collector for a cable battery, a conductive layer formed on the outer surface of the current collector, and a polymer film layer formed on the inner surface of the current collector, includes: a) removing a portion of the conductive layer using a pulse laser, thus exposing the surface of the current collector positioned thereunder, and b) welding a metal tab to the surface of the current collector, thus enabling the welding of a metal tab and an electrode for a cable battery, which has been difficult to achieve using a conventional welding process.