Cylindrical Battery Tab Welding With Single-Pass Laser Joining
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Solution Overview
Problem
Conventional manufacturing of cylindrical secondary batteries requires two separate electrical connections, increasing production costs and time due to the need for two welding processes.
Innovation Solution
A method and apparatus for manufacturing cylindrical secondary batteries that integrate a one-time electrical connection by welding the uncoated portion, current collector, and lead tab simultaneously using a laser welder, facilitated by a pressing pusher to ensure close contact between these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate welding processes are used to connect uncoated portion-current collector-lead tab, then electrical connection reliability is improved, but manufacturing time and production cost increase
Solution Approach 1:
The patent combines two separate welding processes into a single integrated welding operation. The welding device simultaneously welds the uncoated portion to the current collector and the current collector to the lead tab in one continuous action, eliminating the need for separate welding stations and reducing manufacturing time while maintaining connection reliability through optimized single-pass welding parameters
2Strength
If two separate welding processes are used to connect uncoated portion-current collector-lead tab, then connection strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates two welding functions into a single welding device structure. The device includes positioning mechanisms and welding electrodes arranged to perform both welds simultaneously, reducing the number of required welding stations and equipment while achieving adequate connection strength through optimized welding parameters and contact pressure control
Solution Approach 2:
The welding device is designed with multi-functionality to perform multiple welding operations. The same welding electrode and positioning system handle both the uncoated portion-current collector connection and the current collector-lead tab connection, making the device versatile and reducing overall system complexity
3Productivity
If one-time welding is used to connect uncoated portion-current collector-lead tab, then manufacturing efficiency is improved, but welding quality control becomes more difficult
Solution Approach 1:
The patent implements preliminary positioning of the uncoated portion, current collector, and lead tab before the welding operation. The positioning mechanisms ensure correct alignment and contact pressure are established in advance, allowing the single welding pass to produce consistent, high-quality connections without requiring complex real-time control during the welding process itself
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
Reduces production costs and time by eliminating the need for multiple welding stations, enhancing welding quality and efficiency while maintaining high output performance.
Implementation Method 1
electrically connecting the uncoated portion, the current collector, and the lead tab together with one laser welder
Data Source
AI summary
A method of manufacturing a cylindrical secondary battery includes manufacturing an electrode assembly including an electrode plate having an uncoated portion; positioning and arranging a current collector on the uncoated portion of the electrode assembly; positioning and arranging a lead tab on the current collector; and electrically connecting the uncoated portion, the current collector, and the lead tab.