Folded Electrode Plate Structure for Continuous Battery Welding
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Solution Overview
Problem
Conventional rechargeable battery current collectors face challenges in manufacturing efficiency, welding strength, and reliability due to the need for cutting and rolling of strip-shaped materials, which results in poor welding effects and increased risk of short circuits.
Innovation Solution
The electrode plate design incorporates a conductive connector that overlaps a folded region between two conductor layers, allowing for partial cutting and folding of the current collector, enabling continuous production and improved welding stability through ultrasonic welding, while reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If strip-shaped current collector is cut into individual pieces and rolled up for welding, then the current collector can be manufactured, but the manufacturing process becomes complex and continuous production is hindered
Solution Approach 1:
The patent applies continuity of useful action by maintaining the current collector as a continuous strip throughout the manufacturing process. The strip-shaped current collector is not cut into individual pieces but remains continuous while being formed, folded, and welded in a streamlined continuous manufacturing process, thereby improving productivity without compromising ease of manufacture
Solution Approach 2:
The patent applies preliminary action by pre-forming the folded region and blank regions in the continuous strip-shaped current collector before welding. The folding is performed in advance on the continuous strip, creating predetermined folded regions that will later serve as welding positions, eliminating the need for post-cutting and post-folding operations
2Strength
If strip-shaped current collector is rolled up and welded, then the current collector structure is formed, but the roll-up portions cannot fit against welded positions well causing weak welding
Solution Approach 1:
The patent applies preliminary action by pre-forming the folded region in the continuous strip-shaped current collector before welding. The folding is performed in advance to create a predetermined folded region with a flat folded surface, ensuring that the folded portion will align properly with the welding position during the welding process, thereby improving both welding strength and manufacturing precision
Solution Approach 2:
The patent applies self-service by designing the folded region to automatically form a flat folded surface through the folding process itself. The folded structure inherently creates a stable, flat surface that naturally aligns with the welding position, eliminating the need for additional alignment adjustments or complex positioning mechanisms
3Reliability
If thin conductor layers are welded, then the current collector structure is achieved, but welding strength is difficult to ensure and reliability is poor
Solution Approach 1:
The patent applies self-service by designing the folded region to automatically form a flat folded surface through the folding process itself. The folded structure inherently creates a stable, flat surface that naturally aligns with the welding position, eliminating the need for additional alignment adjustments or complex positioning mechanisms
Solution Approach 2:
The patent applies composite materials by using a strip-shaped current collector with a specific structure that includes folded regions and blank regions. The composite structure of the current collector, combining conductive and insulating regions, enables improved welding performance and reliability while maintaining the necessary electrical properties
4Reliability
If polymer support is used in composite current collector, then breakage and piercing probability is reduced, but conductor layers are insulated from each other making it difficult to export currents
Solution Approach 1:
The patent applies segmentation by dividing the current collector into distinct functional regions: folded regions containing conductor layers for current export, and blank regions serving as insulating separators. This segmentation allows the polymer support to provide mechanical strength and safety while the structured arrangement of conductor and blank regions ensures proper electrical insulation and current export capability
Solution Approach 2:
The patent applies local quality by assigning different properties to different regions of the current collector. The folded regions have high electrical conductivity for current export, while the blank regions have insulating properties to separate conductor layers. The polymer support provides localized mechanical strength where needed, while maintaining electrical insulation in appropriate areas
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 enhances the safety and efficiency of rechargeable battery production by facilitating automatic continuous production, improving welding reliability, and reducing labor costs, while maintaining effective electrical connectivity.
Implementation Method 1
improving welding stability through ultrasonic welding
Data Source
AI summary
An electrode plate includes a current collector which includes an insulating layer, a first conductor layer and a second conductor layer disposed on two sides of the insulating layer respectively, and a conductive connector. The outward side of the first conductor layer is provided with a first blank region and a first active material coating layer. The outward side of the second conductor layer is provided with a second blank region and a second active material coating layer. The first blank region is provided with a folded region, and the second blank region covers the first blank region. One end of the conductive connector extends out of the folded region to connect the first blank region. The other end of the conductive connector is connected to the second blank region. The conductive connector is adapted to electrically connect the first blank region and the second blank region.