Cell Tab Tension Measurement During Lead Bending Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

There is no device capable of confirming the possibility of disconnection of a tab in secondary batteries due to applied tension when the lead is bent during assembly, which can lead to tab disconnection.

Innovation Solution

A tab tension measuring device comprising a pair of jigs to fix the tab, a pair of bending dies to bend the lead, and a tension meter to measure the applied tension, preventing tab disconnection by detecting when the tension exceeds a predetermined limit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the lead is bent during assembly to arrange cells on bus bar, then the battery assembly is completed, but the tab may disconnect due to applied tension

Engineering Contradiction:

Improvebattery assemblyVSAvoidtab connection

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by measuring the tab tension before the bending process completes. The tension measurement is performed during the bending operation to detect potential tab disconnection risks before they manifest as actual failures, allowing preventive measures to be taken while the assembly process is still ongoing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by using a tension meter to continuously monitor the tension applied to the tab during the lead bending process. This real-time feedback allows the system to detect when tension exceeds safe thresholds and adjust or stop the bending operation to prevent tab disconnection, creating a closed-loop control system that ensures reliability while maintaining manufacturing efficiency.

Inventive Principle:

Principle #23Feedback

2Productivity

If no tension measurement is performed during lead bending, then the manufacturing process is simple and fast, but tab disconnection cannot be detected

Engineering Contradiction:

Improvemanufacturing speedVSAvoidtab tension

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent replaces complex mechanical tension measurement systems with a simpler sensor-based approach. Instead of using elaborate mechanical devices to measure and control tab tension, the invention employs a tension meter that directly measures the force applied to the tab during bending, converting a mechanically complex measurement problem into a straightforward sensor reading that can be easily integrated into the existing bending process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12535394B2Tab tension measuring device of cell and tab tension measuring method of cell

Publication Date: 2026.01.27 LG ENERGY SOLUTION LTD

AI summary

An embodiment of the present invention provides a tab tension measuring device of a cell including a tab and a lead connected to the tab, including: a pair of jigs fixing the tab; a pair of bending dies bending the lead; and a tension meter connected to the cell to measure the tension applied to the tab when the lead is bent.