Tab Bundle Design for Rechargeable Battery Tab Protection
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Solution Overview
Problem
The existing rechargeable batteries face challenges in integrating the lid with the electrode assembly without applying load on the tabs, which are prone to damage due to their low rigidity, leading to increased electric resistance.
Innovation Solution
The design includes tab bundles with bent and extended portions, and conductive members with fixed and connecting pieces that are insulated from the wall portion, allowing the tabs to be joined to the connecting pieces before integrating the lid, thereby reducing the load on the tabs and enhancing their stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance welding is used to join tab bundles to conductive members, then electrical connection is achieved, but the tabs are prone to damage and electric resistance increases due to low rigidity during subsequent lid integration
Solution Approach 1:
The conductive members are joined to the lid in advance before the tab bundles are connected. This preliminary action allows the lid and conductive members to be integrated first, providing a stable support structure that prevents tab damage during subsequent assembly operations, thereby resolving the contradiction between achieving electrical connection and maintaining tab rigidity
Solution Approach 2:
The conductive member is divided into a fixed piece (joined to the lid) and a connecting piece (joined to the tab bundle). This segmentation allows the fixed piece to provide stable support to the lid structure while the connecting piece flexibly connects to the tab bundle, reducing stress on the tabs and preventing damage while maintaining electrical connection
2Ease of manufacture
If tabs are joined to conductive members before integrating the lid, then electrical connection is established, but the low rigidity of tabs causes them to be under load and easily damaged during lid integration
Solution Approach 1:
The lid and conductive members are integrated in advance before attaching the tab bundles. This preliminary integration creates a stable structural foundation that can support the subsequent attachment of flexible tab bundles without subjecting them to damaging loads, thus maintaining both manufacturing ease and tab integrity
Solution Approach 2:
The conductive member is segmented into a fixed piece that provides rigid support when joined to the lid, and a connecting piece that flexibly connects to the tab bundle. This segmentation allows the structure to be assembled easily while the fixed piece prevents tab damage by providing a stable mounting point
3Reliability
If the lid and electrode assembly are integrated without applying load on tabs, then tab damage is prevented, but it is difficult to achieve proper integration due to low tab rigidity
Solution Approach 1:
The lid and conductive members are integrated in advance before attaching the tab bundles. This preliminary action creates a stable structural framework that can accommodate the flexible tab bundles without applying load to them, thus preventing tab damage while simplifying the integration process by providing a ready-made support structure
Solution Approach 2:
The conductive member is divided into a fixed piece that provides rigid support for the lid integration and a connecting piece that flexibly attaches to the tab bundle. This segmentation allows the lid to be integrated with proper support structures in place, making the process easier while the fixed piece ensures tabs remain protected from loading
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 load on the tabs during integration, stabilizes the conductive members, and minimizes the risk of damage, while also facilitating a more compact and efficient manufacturing process.
Implementation Method 1
The conductive members electrically connect the tab bundles to the electrode terminals
Implementation Method 2
The resistance welding is performed by sandwiching each conductive member and the associated tab bundle between welding electrode rods
Data Source
AI summary
A tab bundle has a first bent portion, which is at a first end in the stacking direction L of an electrode assembly in a laminated state and is bent toward a second end in the stacking direction L of the electrode assembly, and an extended portion, which protrudes from the first bent portion in the stacking direction L. The tab bundle is electrically connected to a conductive member by means of a conduction part, which is located in the extended portion. The conductive member includes: a fixed piece, which is fixed to the inner surface of a lid member and located between the extended portion and the lid member, and a connecting piece, which intersects the fixed piece and protrudes toward the electrode assembly. The tab bundle is electrically connected to the connecting piece by means of the conduction part, which is located in the extended portion.