Deformable Weld Plate for Planar Battery Tab Stack Joining
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Solution Overview
Problem
Existing methods for electrically connecting electrode tabs in battery cells often require pre-welding techniques like ultrasonic welding and can cause deformation or bending of the tab stacks, which compromises the durability and robustness of the connections.
Innovation Solution
A deformable weld plate with planar welding surfaces is used to connect tab stacks without folding or applying bending forces, utilizing a deformable portion that maintains contact during welding, and optionally incorporating clips for secure insertion and compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-welding techniques like ultrasonic welding are used to connect tab stacks, then electrical connection is achieved, but deformation or bending of the tab stacks occurs which compromises connection durability and robustness
Solution Approach 1:
The patent replaces traditional mechanical pre-welding techniques (ultrasonic welding) with a direct welding method using a deformable weld plate. The weld plate's deformable portion allows the system to achieve proper contact and alignment through controlled deformation of the plate itself rather than deforming the tab stacks, thereby substituting a mechanical system that protects the tabs from deformation.
Solution Approach 2:
The weld plate incorporates a deformable portion that can dynamically adjust during the welding process. This deformable section allows the plate to adapt its shape to accommodate the tab stack, ensuring proper contact and alignment without requiring pre-welding operations that would deform the tabs. The dynamic adaptability of the weld plate resolves the contradiction by providing reliability through flexibility.
2Ease of manufacture
If traditional welding methods are used without deformable components, then the welding process is simple, but the tab stacks must be pre-deformed or bent to achieve proper contact, compromising connection robustness
Solution Approach 1:
The deformable weld plate introduces dynamic adaptability to the welding process. The deformable portion can be actuated during welding to achieve proper contact with the tab stack, ensuring robust connections without requiring complex pre-welding operations. This maintains ease of manufacture while significantly improving connection robustness through the plate's ability to adapt during the welding process.
Solution Approach 2:
The patent changes the physical state or configuration of the weld plate (from rigid to deformable) to enable it to adapt during welding. This parameter change allows the system to achieve proper contact and alignment dynamically, improving connection robustness without complicating the manufacturing process. The deformable plate can be actuated to the appropriate configuration during welding and then maintained in that state.
3Reliability
If clips with moveable members are added to the weld plate for secure insertion and compression, then connection robustness is improved, but device complexity increases
Solution Approach 1:
The clips with moveable members provide dynamic clamping action to secure the tab stack during welding. The moveable members can be actuated to apply compression forces, ensuring robust connections. While this adds some structural elements, the clips are integrated into the weld plate design and work in conjunction with the deformable portion, providing enhanced reliability without excessive complexity.
Solution Approach 2:
The clips are merged with the weld plate structure, integrating the clamping function into the existing deformable plate design. This integration reduces overall device complexity by combining multiple functions (welding surface, deformation capability, and clamping action) into a unified structure rather than using separate components.
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
This method enhances the durability and robustness of the welded connections by maintaining the tab stacks in a planar configuration, minimizing deformation, and eliminates the need for pre-welding processes.
Implementation Method 1
a welding device configured to weld the tab stack to the first welding surface and the second welding surface to form at least part of a connector
Data Source
AI summary
A system for electrically connecting tabs of a battery cell includes an electrically conductive weld plate configured to be disposed within a housing of the battery cell and electrically connected to a tab stack formed from a plurality of tabs extending from electrode layers of a cell stack. The weld plate has a first welding surface and a deformable portion that defines a second welding surface, and the deformable portion is configured to be deformed and maintained in a deformed state during welding of the tab stack to the weld plate.