Prismatic Cell Connection Plate for Low-Height Tab Welding
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Solution Overview
Problem
Electrochemical cells of prismatic format face challenges with significant internal volume occupation by tabs, leading to reduced volumetric capacity and increased metal strip usage due to high tab heights, and existing connection methods result in fragile connections and high electrical resistance.
Innovation Solution
The electrochemical cell employs an electrical connection part with a support plate featuring multiple triangular prism connection means aligned parallel to each other, allowing tabs to be connected via weld beads extending parallel to the plate's longitudinal plane, reducing tab height and improving connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are made with conventional height (15-25 mm) to ensure adequate connection surface area, then electrical connection reliability is improved, but internal volume occupation increases and volumetric capacity decreases
Solution Approach 1:
The patent transitions from conventional tab connection (welding on the broad face of the tab) to edge welding (welding on the narrow edge of the tab). This dimensional change in the welding location allows for adequate electrical connection without requiring tall tabs, thereby reducing volume occupation while maintaining connection reliability
Solution Approach 2:
The patent changes the welding parameter from face welding to edge welding, and optimizes the tab height to a specific range (3-10 mm) that balances connection reliability with volume reduction. This parameter optimization resolves the contradiction between connection strength and volume occupation
2Strength
If tab height is increased to provide sufficient welding surface area, then connection strength is improved, but metal strip usage increases and manufacturing cost rises
Solution Approach 1:
The patent moves the welding operation from the broad face of the tab to its narrow edge. This dimensional change in welding location provides sufficient welding surface area without requiring increased tab height, thereby reducing metal strip consumption while maintaining connection strength
Solution Approach 2:
The patent optimizes tab height to 3-10 mm and changes the welding method to edge welding, which together reduce metal strip usage while ensuring adequate connection strength through the optimized welding geometry and process
3Ease of manufacture
If conventional welding methods are used on tab faces, then manufacturing simplicity is maintained, but connection fragility increases and electrical resistance rises
Solution Approach 1:
The patent changes the welding location from the tab face to the tab edge, which fundamentally improves connection reliability by creating a more robust weld joint that is less prone to fragility and electrical resistance issues, while remaining manufacturable with appropriate welding processes
Solution Approach 2:
The patent specifies welding parameters including weld bead geometry (extending parallel to the plate's longitudinal plane) and welding location (edge of the tab), which together improve connection reliability while maintaining manufacturing feasibility through optimized process parameters
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 configuration reduces the height of tabs from 15-25 mm to 3-10 mm, minimizing dead volume and metal strip usage, while enhancing mechanical strength and reducing electrical resistance, thus increasing the cell's volumetric capacity and efficiency.
Implementation Method 1
The tab is welded to a connection means of the connection part
Data Source
AI summary
An electrochemical cell includes a container having a bottom and containing an assembly of parallelepipedal plates consisting of one or more positive plates including positive tabs and negative plates including negative tabs, separated by a separator; one or more covers closing an opening of the container; an electrical connection part of a given polarity connecting a tab of the same polarity to a current output terminal of the cell of the same polarity, fixed to a cover; an electrical connection part of opposite polarity connecting a tab of opposite polarity to a current output terminal of opposite polarity, which is fixed to, and electrically insulated from, the cover, the bottom of the container, or a second cover electrically insulated from the first cover; the connection parts each comprising a support plate having a projecting element for connecting a given polarity tab to the current output terminal of corresponding polarity.