Electrode Tab Emboss Collapse for Reliable Battery Case Welding
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Solution Overview
Problem
Existing secondary battery manufacturing methods lack reliability in the connection between the electrode tab and the battery case, which affects the stability and performance of the battery.
Innovation Solution
A method involving the collapse of an embossed structure of the electrode tab and welding it to the battery case using distinct voltage and current waveforms, ensuring a larger current carrying area through controlled heating and melting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode tab is directly welded to the battery case without collapsing the embossed structure, then the manufacturing process is simpler, but the current carrying area is insufficient and reliability is reduced
Solution Approach 1:
The embossed structure of the electrode tab is collapsed before welding to battery case, preparing the contact surface in advance to ensure sufficient current carrying area. This preliminary deformation of the tab structure allows for better contact area without complicating the welding process itself.
Solution Approach 2:
The contact surface parameters are changed by collapsing the embossed structure, transforming the geometric configuration of the electrode tab to increase the effective contact area with the battery case, thereby improving current carrying capacity.
2Reliability
If a single voltage waveform is used for both softening and welding, then the process is simpler, but the welding quality and reliability are compromised
Solution Approach 1:
The welding process is segmented into two distinct stages with different voltage waveforms: a first voltage waveform for softening the electrode tab material, and a second voltage waveform for actual welding. This segmentation allows each stage to be optimized independently for its specific function.
Solution Approach 2:
The welding process employs periodic application of different voltage waveforms, first applying a softening waveform to prepare the material, then applying a welding waveform to create the bond. This periodic variation in electrical parameters ensures both material preparation and welding quality.
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 approach enhances the stability and reliability of the battery by increasing the current carrying area between the electrode tab and the battery case, improving the welding process.
Implementation Method 1
The first voltage waveform applied to the electrode tab may soften the electrode tab. A temperature of the electrode tab to which the first voltage waveform is applied may be less than or equal to a melting point of the electrode tab.
Implementation Method 2
The second voltage waveform applied to the electrode tab may melt the electrode tab. The temperature of the electrode tab to which the second voltage waveform is applied may be greater than or equal to the melting point.
Data Source
Figure 1
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AI summary
Example embodiments provide a secondary battery manufacturing method. The secondary battery manufacturing method includes collapsing an embossed structure of an electrode tab and welding a battery case to a collapsed part of the embossed structure.