Battery Terminal Base Plate Structure for Direct Tab Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery manufacturing processes are complex and costly due to the need for multiple welding steps, including the use of connecting plates, which increases the welding cost and reduces energy density as the size of the cell increases.
Innovation Solution
A battery design where the tab is directly welded to a base plate within the terminal, eliminating the need for a connecting plate and simplifying the manufacturing process by integrating the base plate as part of the terminal, allowing for ultrasonic and laser welding techniques to form the tab and terminal connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a connecting plate is used to connect the tab to the terminal, then the structural strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The base plate is integrated as an integral part of the terminal structure, merging two previously separate components (connecting plate and terminal) into one unified component. This eliminates the need for separate connecting plates while maintaining structural strength through the unified design.
Solution Approach 2:
The base plate serves multiple functions simultaneously: it acts as both the connecting element for the tab and the terminal structure itself, eliminating the need for separate connecting plates. This multi-functional design reduces component count and simplifies the overall device structure.
2Strength
If a connecting plate is used to connect the tab to the terminal, then the structural strength is improved, but the welding cost and manufacturing time increase
Solution Approach 1:
By integrating the base plate into the terminal structure, the patent eliminates the sequential welding process (tab to connecting plate, then connecting plate to terminal) and replaces it with a single welding operation (tab directly to base plate), significantly reducing manufacturing time and welding costs.
Solution Approach 2:
The base plate is pre-integrated into the terminal structure during terminal manufacturing, so that when assembly occurs, the tab can be directly welded to the already-positioned base plate without requiring intermediate connecting plates or additional welding steps.
3Ease of manufacture
If the base plate size is increased to facilitate direct welding, then the welding process is simplified, but the weight of the cell increases
Solution Approach 1:
The base plate is designed with non-uniform thickness distribution, with thicker regions positioned at the welding location to facilitate direct tab welding, and thinner regions in other areas to minimize overall weight. This localized quality variation optimizes both weldability and weight characteristics.
Solution Approach 2:
The base plate's geometric parameters (thickness, dimensions, shape) are optimized to achieve the minimum required size for effective welding while minimizing weight. The parameters are carefully selected to balance welding accessibility with weight reduction goals.
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 reduces the weight of the cell structural members, simplifies the welding process, lowers manufacturing costs, and improves energy density by optimizing the size and structure of the terminal's base plate, while preventing damage to sealing components during welding.
Implementation Method 1
The electrode leads form the tab through ultrasonic welding
Implementation Method 2
the tab is laser welded to the base plate
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery is provided. The battery includes a cell, including a tab (31); a casing (4), including an opening, wherein the cell is accommodated in the casing (4); a cover plate assembly (2), covering the opening; and a terminal (1), fixed onto the cover plate assembly (2) and including a terminal body (12) penetrating the cover plate assembly (2) and a base plate (11) disposed on a back surface of the cover plate assembly (2). The tab (31) is welded to the base plate (11).