Slotted Internal Battery Terminals for Reliable Laser Tab Welding
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Solution Overview
Problem
The existing methods for laser welding internal terminals in battery cells face difficulties due to the complexity of aligning and welding external tabs of cathode and anode electrodes, which affects the reliability and efficiency of the process.
Innovation Solution
The use of internal terminals with strategically designed slots and configurations, such as open-ended or multiple slots, allows for improved alignment and welding of external tabs, enabling effective laser welding of cathode and anode electrodes to internal terminals, enhancing the electrical connection and structural integrity of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional alignment methods are used for welding external tabs to internal terminals, then the alignment process becomes complex and time-consuming, but the welding reliability is compromised
Solution Approach 1:
The patent applies preliminary action by pre-forming the external tabs with predetermined bending shapes and pre-positioning them on the electrodes before assembly. This preliminary preparation ensures that when the tabs are inserted into the internal terminal slots, they automatically align correctly without requiring complex real-time alignment procedures during the welding process, thereby maintaining high welding reliability while simplifying the overall process.
2Ease of manufacture
If multiple slots are used in internal terminals for tab insertion, then the welding process becomes simpler and more reliable, but the manufacturing complexity of internal terminals increases
Solution Approach 1:
The patent applies segmentation by dividing the internal terminal structure into multiple discrete slots, each designed to receive specific external tabs. This segmentation allows each slot to be independently optimized for its specific tab's insertion and welding requirements, simplifying the welding process for each individual connection. While the overall terminal structure becomes more complex, the modular slot design makes the internal terminal manufacturable using standard fabrication techniques.
3Reliability
If external tabs are folded and welded through slots, then the electrical connection reliability improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by designing slots with specific local geometric features such as tapered entrances, rounded corners, and optimized dimensions that guide the external tabs into correct positions during insertion. These localized structural modifications create self-aligning conditions that reduce the precision requirements for tab folding and welding operations, while still achieving reliable electrical connections through the welded joints.
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 simplifies the laser welding process, increases the reliability of electrical connections, and enhances the structural integrity of battery cells by ensuring secure and efficient bonding of external tabs to internal terminals.
Implementation Method 1
portions of the external tabs of the one of the C cathode electrodes and the A anode electrodes extend through the first slot, are folded and laser welded to a surface of the first internal terminal
Data Source
AI summary
A battery cell includes a stack including C cathode electrodes, A anode electrodes, and S separators, where C, A and S are integers greater than one. A first internal terminal includes a first slot. The external tabs of one of the C cathode electrodes and the A anode electrodes are inserted into the first slot. One of edges of the external tabs of one of the C cathode electrodes and the A anode electrodes are laser welded in the first slot, and portions of the external tabs of the one of the C cathode electrodes and the A anode electrodes extend through the first slot, are folded and laser welded to a surface of the first internal terminal.