Ceramic Tab Pressing Structure for Battery Tab Laser Welding
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Solution Overview
Problem
In the manufacturing of secondary batteries, particularly prismatic or circular types, achieving effective laser welding of the negative electrode tab to the case requires precise close contact, which is challenging due to the need for consistent pressure and heat resistance, often leading to potential damage and electrical short circuits.
Innovation Solution
A pushing unit with a rod and a tab pressing portion made of ceramic material, such as alumina or zirconia, is used to press the electrode tab against the case bottom, ensuring close contact and heat resistance, minimizing damage and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a metal pusher is used to press the electrode tab against the case bottom, then sufficient pressing force is achieved, but the pusher may be damaged by welding heat causing electrical short circuits
Solution Approach 1:
The pusher is constructed as a composite structure combining a metal rod (for mechanical strength and pressing force) with a ceramic coating or ceramic material tab pressing portion (for heat resistance). This composite design allows the pusher to maintain sufficient pressing force while resisting welding heat damage, preventing electrical short circuits.
Solution Approach 2:
A ceramic layer is introduced as an intermediary between the metal rod and the electrode tab/case bottom contact area. This ceramic intermediary provides the heat resistance property that the metal lacks, while the metal rod provides the structural integrity and pressing force. The ceramic acts as a mediator that protects the metal from direct heat exposure.
2Manufacturing precision
If pressure is applied to ensure close contact for welding, then welding quality improves, but the pushing unit may be damaged by high temperature
Solution Approach 1:
The tab pressing portion uses ceramic material or ceramic coating that inherently resists high temperatures while maintaining mechanical properties suitable for pressing. This allows the pushing unit to apply sufficient pressure for close contact during welding without suffering thermal damage, ensuring both welding quality and pusher durability.
Solution Approach 2:
The material properties of the tab pressing portion are changed from metal to ceramic or ceramic-coated, fundamentally altering the thermal resistance parameter. This material parameter change enables the pushing unit to operate in high-temperature welding environments without damage, while maintaining the mechanical pressing capability needed for close contact.
3Reliability
If a ceramic material is used for the tab pressing portion, then heat resistance is improved, but the structural strength may be reduced
Solution Approach 1:
The pusher employs a composite structure where the metal rod provides the primary structural strength and load-bearing capability, while the ceramic coating or ceramic material tab pressing portion provides heat resistance. This division of functional roles allows each material to excel at its specialized property, with the metal ensuring structural integrity and the ceramic ensuring thermal resistance.
Solution Approach 2:
The ceramic material or coating is applied locally only to the tab pressing portion that contacts the electrode tab and case bottom, rather than making the entire pusher ceramic. This localized application provides heat resistance exactly where needed (at the contact interface exposed to welding heat) while maintaining the overall structural strength of the metal rod body.
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
The ceramic tab pressing portion enhances the welding process by providing superior heat resistance and durability, ensuring reliable electrode tab attachment without damage, thereby improving manufacturing stability and safety.
Implementation Method 1
a tab pressing portion at an end portion of the rod having a relatively higher heat resistance than the rod
Implementation Method 2
welding the electrode tab to the bottom of the case
Data Source
AI summary
An apparatus for manufacturing a secondary battery and a method for manufacturing a secondary battery using the apparatus, the apparatus for manufacturing a secondary battery including a rod extending in a longitudinal direction and a tab pressing portion at an end portion of the rod having a relatively higher heat resistance than the rod.