Lithium Electrode Tab Bonding With Mold-Controlled Joint Uniformity
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Solution Overview
Problem
The conventional methods for bonding lithium electrode tabs and metal leads in lithium secondary batteries face challenges in achieving uniform shape, thickness, and bonding area, leading to inconsistent bonding strength and increased resistance variations, along with production inefficiencies and defects due to the soft nature of lithium and adherence issues.
Innovation Solution
A method involving a mold to position and pressurize the lithium electrode tab and metal lead, allowing for controlled shaping and bonding, which ensures uniformity in the bonding area and strength, and prevents lithium adherence to the pressurizing device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressurization method is used to bond lithium electrode tab and metal lead, then bonding is achieved, but bonding strength and bonding area cannot be uniformly controlled
Solution Approach 1:
A mold is introduced as an intermediary device between the pressurization mechanism and the lithium electrode tab. The mold includes a cavity that receives the lithium electrode tab and defines a bonding area, allowing uniform pressure distribution across the bonding interface while preventing excessive spread of the soft lithium material.
Solution Approach 2:
The mold cavity dimensions are specifically designed to control the bonding area size and shape. By adjusting the cavity parameters (width, length, depth), the bonding area can be precisely controlled to achieve uniform bonding strength while maintaining consistent geometric parameters across different battery cells.
2Ease of manufacture
If pressurization is applied to bond lithium electrode tab, then bonding occurs, but lithium adheres to pressurizing device causing defects
Solution Approach 1:
The mold acts as an intermediary that prevents direct contact between the lithium electrode tab and the pressurizing device. The pressurization force is applied to the mold, which then transfers it uniformly to the lithium material within the cavity, eliminating adherence issues while maintaining bonding effectiveness.
Solution Approach 2:
The harmful adherence effect is extracted and isolated by introducing the mold as a separate component. The lithium material remains contained within the mold cavity throughout the pressurization process, preventing contact with and adherence to the pressurizing device surfaces.
3Productivity
If conventional pressurization is used without mold, then bonding is achieved, but production efficiency is low due to bonding defects
Solution Approach 1:
The mold serves as a standardized intermediary component that ensures consistent bonding quality across all production units. By controlling the bonding area and pressure distribution through the mold cavity, defect rates are reduced and production efficiency is improved through more reliable, repeatable bonding processes.
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 enables uniform formation of the lithium electrode tab's shape and thickness, adjusts bonding strength, minimizes resistance variations, and enhances production efficiency by reducing defects and adherence issues, resulting in improved bonding quality and battery performance.
Implementation Method 1
pressurizing an upper portion of the metal lead stacked on the lithium electrode tab
Implementation Method 2
positioning one end of the lithium electrode tab in a molding groove of the mold
Data Source
AI summary
A method of bonding a lithium electrode tab and a metal lead using a mold, and a lithium secondary battery comprising a bonding structure of the lithium electrode tab and the metal lead manufactured by the same are provided. The method comprises preparing a mold, positioning one end of the lithium electrode tab in a molding groove of the mold, stacking one end of the metal lead on an upper portion of the lithium electrode tab positioned in the molding groove, and pressurizing an upper portion of the metal lead stacked on the lithium electrode tab.