Electrode Plate Tab Assembly Without Welding for Stable Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing cost of electrode plate assemblies in electrochemical devices is high due to the need for welding, which is costly and prone to defects, and involves additional production steps to expose current collectors for welding, increasing overall production costs.
Innovation Solution
An electrode plate assembly with a tab that includes a main body and a constraining portion, where the tab is connected through a through-hole in the electrode plate without welding, allowing continuous coating and reducing production steps, with the active material layers positioned between the tab components to enhance stability and prevent wobbling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect the tab to the electrode plate, then the connection strength is improved, but the manufacturing cost increases and welding defects occur
Solution Approach 1:
The patent replaces the welding process with a mechanical insertion method. The tab is inserted through a through-hole in the electrode plate and fixed using a rivet or pin, eliminating the need for welding equipment and processes. This substitution reduces manufacturing cost and avoids welding defects while maintaining connection strength through mechanical fastening.
Solution Approach 2:
The patent introduces an intermediary component (through-hole with rivet or pin) to connect the tab to the electrode plate. This intermediary mechanical fastening system serves as a mediator between the tab and electrode plate, providing a reliable connection alternative to welding that reduces cost and complexity.
2Strength
If welding is used to connect the tab to the electrode plate, then the connection strength is improved, but the production steps increase due to coating removal
Solution Approach 1:
By replacing welding with mechanical insertion through a through-hole, the patent eliminates the need to remove active material coating to expose the current collector. The tab is inserted through the coating and fixed with a rivet or pin, allowing continuous coating without additional removal steps, thereby reducing production complexity and improving productivity.
3Ease of manufacture
If the tab is connected without welding through a through-hole, then the manufacturing cost is reduced, but the connection stability may be compromised
Solution Approach 1:
The patent segments the connection structure into distinct components: the through-hole in the electrode plate, the tab, and the rivet or pin fastener. This segmentation allows each component to be optimized independently and assembled through simple insertion, reducing manufacturing cost while maintaining reliable connection through the mechanical interlocking of the segmented parts.
Solution Approach 2:
The mechanical insertion system is self-service in nature, requiring no external energy source or complex equipment. The tab is simply inserted through the through-hole and secured with a rivet or pin, creating a self-contained connection mechanism that is both cost-effective and reliable without requiring welding expertise or equipment.
Data Source
AI summary
An electrode plate assembly includes an electrode plate and a tab. A first through-hole is created on the electrode plate. The first through-hole penetrates the electrode plate along a thickness direction of the electrode plate. The tab includes a main body, a connecting portion, and a constraining portion. Along the thickness direction, the main body and the constraining portion are located on two sides of the electrode plate respectively. The connecting portion runs through the first through-hole and connects the main body and the constraining portion. The electrode plate includes a current collector and a first active material layer. Along the thickness direction, the first active material layer is disposed on one side of the current collector. The current collector and the first active material layer are located between the main body and the constraining portion. The tab is electrically connected to the current collector.