Notched Full-Tab Pole Piece for Flat Core Ends
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Solution Overview
Problem
In battery manufacturing, the process of smoothing or flattening full-tab pole pieces often results in overlapping and misalignment, leading to uneven core ends and low stability in welding to busbars, which affects the overall performance of battery products.
Innovation Solution
A pole piece design featuring tabs with notches at their ends, which helps release internal stress and reduce warping deformation, thereby improving the flatness and consistency of the core's end surface and ensuring stable welding to busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tabs are smoothed or flattened in the manufacturing process, then the end surface of the core is formed, but overlapping and misalignment occur causing uneven end surface and low welding stability
Solution Approach 1:
The notch is formed at the end of the tab before the smoothing or flattening process. This preliminary structural modification allows the tab to release internal stress during subsequent bending operations, preventing warping and deformation that would otherwise occur during the smoothing process, thereby ensuring both flatness and welding stability
Solution Approach 2:
The tab structure is segmented by introducing a notch that divides the tab into distinct regions. This segmentation allows different parts of the tab to deform independently during smoothing, reducing internal stress concentration and preventing overall warping, which maintains both end surface quality and welding reliability
2Manufacturing precision
If the width of the tab is reduced to improve congruence of the end surface, then the flatness improves, but internal stress increases causing warping and deformation
Solution Approach 1:
The notch is essentially an extracted or removed portion from the tab structure. By taking out material at the end of the tab to form the notch, internal stress is relieved and the tab can maintain better shape congruence without excessive warping during the smoothing process
3Shape
If multiple tabs are transformed into annular shape through smoothing, then the end surface is formed, but overlapping and misalignment reduce welding stability
Solution Approach 1:
The notch is formed before the smoothing process to preemptively address potential warping issues. This preliminary structural preparation ensures that when tabs are bent into the annular shape, they maintain proper alignment and do not overlap or misalign, preserving welding stability
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
The proposed pole piece design enhances the flatness and consistency of the core's end surface, improves the stability of welding to busbars, and thus ensures the performance and reliability of battery products.
Implementation Method 1
a notch is formed at an end of each tab... the notch is configured to release the internal stress of the tab... weaken the deformation of the tab
Data Source
AI summary
Provided are a pole piece, a core, and a cell. The cell includes the pole piece. The pole piece includes a pole piece body and tabs. Multiple tabs are disposed on an edge of the pole piece body and at intervals in a first direction. A notch is formed at the end of each tab facing away from the pole piece body.