Pouch Cell Tab Assembly With Protective Member Against Welding Damage
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Solution Overview
Problem
Ultra-thin electrochemical apparatuses face issues with tab assembly detachment due to welding damage during manufacturing, leading to safety concerns such as burrs, abnormal protrusions, and cycling performance degradation.
Innovation Solution
Incorporating a soft package film, electrode assembly, and a first protective member, where the electrode assembly includes extension portions stacked on the protective member, forming an adapting portion, and a tab is welded to this structure to reduce welding damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tab layers are welded directly to the welding base during manufacturing, then the tab assembly can be formed efficiently, but the tab layers are prone to damage and detachment
Solution Approach 1:
The patent introduces a protective film as an intermediary layer between the tab layers and the welding base during the welding process. This protective film prevents direct contact and damage to the tab layers, thereby improving welding reliability without compromising manufacturing efficiency. The protective film is temporarily applied during welding and then removed after the welding process is complete.
Solution Approach 2:
The patent applies a protective film to the tab layers before the welding process begins. This protective film acts as a cushioning layer that absorbs or distributes the mechanical stress and heat during welding, preventing damage to the tab layers. The protective film is removed after welding is complete, leaving the tab assembly intact and stable.
2Length of moving object
If the electrochemical apparatus is made ultra-thin to meet consumer product requirements, then the energy density and thickness requirements are satisfied, but the tab assembly becomes more susceptible to welding damage and detachment
Solution Approach 1:
The protective film serves as an intermediary that shields the tab layers from welding-induced damage. In ultra-thin electrochemical apparatus where the structure is more vulnerable, this protective layer is particularly important as it compensates for the reduced structural margin, preventing tab layer detachment while maintaining the ultra-thin profile.
Solution Approach 2:
The patent modifies the welding parameters and process conditions to accommodate ultra-thin structures. By controlling welding temperature, pressure, and duration, and by using the protective film to distribute stress, the welding process is adapted to prevent damage to the more vulnerable tab layers in ultra-thin devices.
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 protective member reduces the probability of detachment, enhancing the safety of the electrochemical apparatus by minimizing welding-induced damage and maintaining structural integrity.
Implementation Method 1
the other ends of the plurality of first extension portions and the first protective member are welded to form a first adapting portion
Data Source
AI summary
An electrochemical apparatus includes a soft package film, an electrode assembly, a first tab, and a first protective member. The electrode assembly is accommodated within the soft package film, and the electrode assembly includes an electrode body and a plurality of first extension portions. One end of each of the plurality of first extension portions is connected to the electrode body, the plurality of first extension portions are sequentially stacked along a first direction, the other ends of the plurality of first extension portions are stacked on the first protective member, and the other ends of the plurality of first extension portions and the first protective member are welded to form a first adapting portion. One end of the first tab is welded to the first adapting portion, and another end of the first tab extends out of the soft package film.