Pouch Cell Clad Electrode Leads for Stronger Laser-Welded Tabs
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Solution Overview
Problem
Conventional methods for connecting electrode tabs and leads in pouch-type battery cells face issues such as high manufacturing costs due to the use of nickel, corrosion vulnerability of aluminum leads, and frequent welding failures, especially with multi-layered electrode tabs, which are prone to external impacts and require broadening the surface area.
Innovation Solution
The use of friction-welded clad metal electrode leads, composed of copper and aluminum, allows for laser-welding with electrode tabs, enhancing weldability and durability, eliminating the need for expensive nickel and ensuring secure connections under high output voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nickel or nickel-plated copper is used for electrode leads to enable soldering, then ease of manufacture is improved, but manufacturing cost increases
Solution Approach 1:
The invention extracts nickel from the electrode lead structure, using only aluminum for both the lead body and tab connection. This eliminates the need for nickel plating or nickel-based materials while maintaining solderability through proper aluminum surface treatment and welding processes.
Solution Approach 2:
The invention replaces expensive nickel materials with cheaper aluminum materials for electrode leads and tabs. Although aluminum requires different joining methods, the cost reduction is achieved by eliminating nickel entirely from the structure.
2Quantity of substance
If aluminum is used for positive electrode lead to reduce cost, then manufacturing cost is reduced, but reliability deteriorates due to corrosion vulnerability and poor soldering
Solution Approach 1:
The invention replaces the traditional soldering mechanical process with laser welding or friction welding. This substitution enables reliable joining of aluminum electrode leads and tabs without requiring nickel plating, as the welding processes directly bond aluminum surfaces with high strength and corrosion resistance.
3Ease of manufacture
If ultrasonic welding is used for aluminum electrode leads, then ease of manufacture is improved, but reliability deteriorates due to frequent welding failures and vulnerability to external impacts
Solution Approach 1:
The invention replaces ultrasonic welding with laser welding or friction welding. These welding methods provide deeper penetration, stronger bonds, and better resistance to external impacts and vibrations, eliminating the welding failures associated with ultrasonic welding of aluminum.
4Reliability
If the surface area of electrode tab is broadened to accommodate multiple electrode tabs, then reliability is improved for welding, but device complexity increases and manufacturing becomes difficult
Solution Approach 1:
The invention replaces traditional broadening of electrode tab surface area with direct laser welding or friction welding of aluminum tabs. These welding methods can reliably join aluminum tabs of standard dimensions without requiring increased surface area, thereby maintaining simple electrode assembly structures while achieving high welding reliability.
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 method results in a pouch-type battery cell with improved weldability, reduced weight, and enhanced durability, capable of withstanding physical impacts while maintaining high output power and capacity.
Implementation Method 1
preparing an electrode lead of clad metal to be welded to each of a positive electrode tab formed on the positive electrode plate and a negative electrode tab formed on the negative electrode plate
Implementation Method 2
laser-welding an end of a positive electrode lead of clad metal to the positive electrode tab, laser-welding an end of a negative electrode lead of clad metal to the negative electrode tab
Data Source
Figure 1~3
Figure 2
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AI summary
A method of manufacturing a pouch-type battery cell comprises preparing (S10) an electrode assembly (10) including a positive electrode plate (101) , a separation film (102), and a negative electrode plate (103), preparing (S20) an electrode lead (20) of clad metal to be welded to each of a positive electrode tab (101a) formed on the positive electrode plate (101) and a negative electrode tab (103a) formed on the negative electrode plate (103a), laser-welding (S30) an end of a positive electrode lead (201) of clad metal to the positive electrode tab (101a), laser-welding (S40) an end of a negative electrode lead (202) of clad metal to the negative electrode tab (103a), attaching (S50) a sealing film (30) to each of the positive electrode lead (201) and the negative electrode lead (202), packing (S60) the electrode assembly (10) in a pouch case (40) after the sealing film (30) is attached, injecting (s70) an electrolyte into an inside of the electrode assembly-packed pouch case (40), and sealing (S80) the electrolyte-injected pouch case (40).