Battery Cell Terminal Coupling Structure for External Weld Inspection
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Solution Overview
Problem
Conventional battery cell manufacturing methods using ultrasonic welding inside the electrode assembly lead to defects due to foreign substances like fumes and spatter, affecting the internal configuration and rigidity, and make it difficult to confirm welding quality.
Innovation Solution
A battery cell design where the electrode terminal and current collector are welded outside the cell case, using a protrusion and welding space formed between the electrode terminal and a coupling hole, allowing for external welding and improved rigidity, reduced damage, and easier quality confirmation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is performed through the hollow space of the electrode assembly inside the cell case, then the current collector and electrode terminal can be electrically connected, but welding foreign substances such as fume or spatter are formed inside the battery cell causing defects
Solution Approach 1:
The patent inverts the welding approach by performing welding from the outside of the cell case rather than from the inside through the electrode assembly hollow space. The current collector extends outward from the electrode assembly, allowing the welding horn to access the welding area externally, thus preventing foreign substances from entering the cell interior.
Solution Approach 2:
The patent extracts the welding operation from the internal hollow space of the electrode assembly and relocates it to the external environment. By extending the current collector outward and performing welding externally, the harmful welding byproducts are separated from the cell interior, eliminating contamination issues.
2Reliability
If welding is performed inside the cell case through the electrode assembly, then electrical connection is achieved, but it is difficult to confirm welding shape and welding quality
Solution Approach 1:
The patent inverts the welding accessibility by performing welding from the outside rather than through the internal hollow space. This external access allows direct visual and measurement inspection of the welding area, making it easy to confirm welding shape and quality without disassembling or accessing the cell interior.
3Reliability
If ultrasonic welding is performed through the hollow space of the electrode assembly, then the current collector and electrode terminal can be welded, but damage to the electrode assembly due to welding heat occurs
Solution Approach 1:
The patent extracts the welding operation from the internal environment and performs it externally on the current collector that extends outward. This separation allows the welding heat to be applied away from the electrode assembly, preventing thermal damage to the sensitive electrode structures while still achieving the required electrical connection.
4Reliability
If the current collector and electrode terminal are welded inside the cell case, then electrical connection is achieved, but foreign substances affect the internal configuration of the battery cell
Solution Approach 1:
The patent extracts the welding operation from the cell interior and performs it externally on the protruding current collector. This separation ensures that welding foreign substances are generated outside the cell, preventing contamination of the internal configuration including the electrode assembly and electrolyte, while maintaining electrical connection integrity.
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
Prevents foreign substances from entering the cell, reduces welding-related damage, and enhances the ability to confirm welding quality, thereby improving the manufacturing process and battery performance.
Implementation Method 1
a welding area may be formed in the welding space by welding performed on an outer side (outside) of the cell case
Data Source
AI summary
The present disclosure provides a battery cell including: a cell case including a side wall having an accommodation space and an upper plate having a through-hole; an electrode terminal coupled to the through-hole and having a coupling hole; an electrode assembly disposed in the accommodation space; and a first current collector electrically connecting the electrode terminal and the electrode assembly, where the first current collector includes a connection terminal having a protrusion inserted into the coupling hole, a welding space is formed between an upper end of a side surface of the protrusion and an inner surface of the coupling hole, and a welding area is formed in the welding space by welding performed on an outer side of the cell case in a state in which the protrusion is inserted into the coupling hole.