Foam Metal Current Collector Edge Structure for Laser Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current collectors made of foam metal are difficult to connect to a housing using laser welding due to laser leakage, leading to scalding and potential explosions, which complicates the battery cell production process.
Innovation Solution
A current collector design incorporating a porous foam metal part and a solid metal part, where the solid metal part is connected to the edges of the foam metal part to prevent laser leakage and serve as a welding area, ensuring stable attachment and preventing arching of the separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a porous foam metal current collector is used, then the battery energy density is improved, but laser welding becomes difficult due to laser leakage
Solution Approach 1:
The current collector is divided into two distinct parts: a porous foam metal part (providing high energy density) and a solid metal part (enabling laser welding). This segmentation allows each part to fulfill its specific function without compromise.
Solution Approach 2:
Different regions of the current collector have different structural qualities - the foam metal part has a porous structure optimized for energy storage, while the solid metal part has a dense structure optimized for welding. This local differentiation resolves the contradiction between energy density and manufacturability.
2Ease of manufacture
If laser welding is performed on foam metal, then connection to housing is achieved, but laser leakage causes scalding and potential explosions
Solution Approach 1:
The solid metal part acts as an intermediary between the foam metal current collector and the housing during laser welding. It receives the laser beam and transfers the connection force to the foam metal part, preventing direct laser exposure of the porous structure and eliminating laser leakage hazards.
3Reliability
If the solid metal part thickness exceeds the foam metal part thickness, then welding stability is improved, but the separator may arch
Solution Approach 1:
The thickness of the solid metal part is precisely controlled to be less than or equal to the thickness of the foam metal part. This parameter optimization ensures adequate welding stability while preventing excessive thickness that would cause separator arching.
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 design effectively prevents laser leakage and scalding, allowing for successful laser welding of the current collector to the housing, maintaining the porosity and uniformity of the foam metal while ensuring stable attachment and preventing pressure deformation.
Implementation Method 1
the solid metal part is used as the welding area of the current collector. When laser welding is performed, the solid metal part can effectively prevent laser leakage
Data Source
AI summary
The present application discloses a current collector, and manufacturing method and equipment thereof, and a current collector preform, wherein the current collector may include a porous foam metal part and solid metal part(s); the porous foam metal part may be uncompressed, and the porous foam metal part may include a first edge and a second edge oppositely distributed in a first direction, the first direction may be perpendicular to the thickness direction of the current collector; the first edge and/or the second edge may be connected with the solid metal part(s).