Electrode Tab Guide Assembly for Tension-Balanced Welding

Solution Overview

Problem

Existing welding methods for electrode tabs in secondary batteries apply excessive tension to the outermost tab, leading to breakage and disconnection due to external forces or deformation during the welding process.

Innovation Solution

A welding apparatus and method that uses a pair of guides with elevation and rotation parts to gather and pull electrode tabs towards the stack, increasing the length between the stack and the welded portion, particularly for the outermost tab, using ultrasonic welding to secure the tabs without breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrode tabs are welded in a conventional manner, then welding can be completed, but excessive tension is applied to the outermost electrode tab causing breakage and disconnection

Engineering Contradiction:

Improveelectrode tab connection reliabilityVSAvoidelectrode tab strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The guides perform preliminary action by gathering and positioning the electrode tabs in a bundled state before the welding process begins. This preliminary arrangement ensures that the tabs are properly aligned and supported, preventing excessive tension during welding. The guides maintain this preparatory configuration throughout the welding operation to protect the outermost tabs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The guides act as intermediary elements between the welding apparatus and the electrode tabs. They mediate the welding process by providing mechanical support and tension distribution, isolating the vulnerable outermost tabs from direct stress. The guides transfer and distribute forces evenly across all tabs, preventing concentration of tension on the outermost tab.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If external force bends the electrode lead, then the lead moves to one side, but excessive tension is applied to the outermost electrode tab causing breakage

Engineering Contradiction:

Improveelectrode assembly flexibilityVSAvoidelectrode tab connection reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The guides provide beforehand cushioning by positioning and supporting the electrode tabs in a bundled configuration before external forces can cause bending. This preparatory support acts as a cushion that absorbs and distributes external forces, preventing excessive tension from reaching the outermost tab during lead movement or bending events.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If electrode tabs are greatly deformed during welding, then welding can be performed, but excessive tension is applied to the outermost electrode tab causing breakage

Engineering Contradiction:

Improvewelding process feasibilityVSAvoidelectrode tab strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The guides perform preliminary action by gathering and positioning the electrode tabs in a bundled state before the welding process begins. This preliminary arrangement ensures that the tabs are properly aligned and supported, preventing excessive tension during welding. The guides maintain this preparatory configuration throughout the welding operation to protect the outermost tabs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The guides act as intermediary elements between the welding apparatus and the electrode tabs. They mediate the welding process by providing mechanical support and tension distribution, isolating the vulnerable outermost tabs from direct stress. The guides transfer and distribute forces evenly across all tabs, preventing concentration of tension on the outermost tab.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 breakage and disconnection of the outermost electrode tab by distributing tension evenly, enhancing the safety and reliability of the electrode assembly.

Implementation Method 1

using ultrasonic welding to secure the tabs without breakage

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS12583062B2Welding apparatus, welding method, and electrode assembly

Publication Date: 2026.03.24 LG ENERGY SOLUTION LTD

AI summary

A welding apparatus configured to weld a plurality of electrode tabs of an electrode assembly, the welding apparatus including a pair of guides configured to gather the plurality of electrode tabs and a welding part configured to weld the plurality of electrode tabs gathered by the pair of guides. Each of the guides including an elevation part elevated with respect to the electrode tabs and a rotation part configured to rotate with respect to the elevation part when each of the electrode tabs is pressed so as to pull the electrode tabs toward the electrode assembly.