Reusable Test Jig for Ultrasonic-Welded Battery Electrode Leads
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Solution Overview
Problem
The existing methods for performing tensile tests on ultrasonic-welded portions of secondary battery electrode leads result in the battery being unusable post-test, leading to increased costs due to unnecessary waste and inefficiency.
Innovation Solution
A reusable test jig shaped like a cell, with insertion parts, a fixing member, guide protrusions, buffer pads, and a latch system, allows for the fixation and testing of electrode leads without requiring an additional cell, enabling efficient and cost-effective tensile testing of ultrasonic-welded portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cell is used to perform tensile test on ultrasonic-welded portion of electrode lead, then the tensile test can be performed, but the cell cannot be reused after testing leading to increased cost
Solution Approach 1:
The test system is segmented into two independent parts: a reusable test jig that provides the testing framework, and a disposable cell that serves only as a placeholder. The cell is divided into functional components (jig main body mimicking cell structure, electrode lead insertion part, fixing member) that can be independently manufactured and assembled, allowing the testing apparatus to be separated from the test subject.
Solution Approach 2:
The test jig acts as an intermediary device that mediates between the testing requirement and the cell. Instead of directly testing the cell, the jig provides a controlled environment with standardized interfaces (insertion part, fixing member, guide groove) that enable consistent tensile testing while protecting the cell from damage and allowing jig reuse.
2Productivity
If additional cells are used for tensile testing, then testing can be performed, but unnecessary costs increase due to waste
Solution Approach 1:
The test jig is designed with universal functionality to perform tensile tests on multiple different cells. The standardized insertion part and fixing member can accommodate various electrode lead configurations, making the jig a multi-purpose tool that can be reused across different testing scenarios rather than requiring dedicated test setups for each cell.
Solution Approach 2:
The jig main body is designed to copy or mimic the external structure and dimensions of an actual cell, allowing it to function as a test platform without requiring a real cell. This copying approach enables the creation of a surrogate testing environment that maintains all necessary mechanical interfaces while eliminating the need to consume actual battery cells for testing purposes.
3Strength
If electrode lead is fixed using additional components, then secure fixation is achieved, but device complexity increases
Solution Approach 1:
The fixing member is merged with the jig main body to form an integrated assembly. The fixing member is detachably coupled to the insertion part, combining the functions of structural support, electrode lead fixation, and test sample mounting into a single unified component that reduces the number of separate parts and simplifies the overall device architecture.
Solution Approach 2:
The fixing mechanism incorporates dynamic elements including a guide groove that allows controlled movement and positioning of the electrode lead during insertion, and a latch part that provides secure fixation after positioning. This dynamic approach allows the system to transition from a loose state during insertion to a firmly locked state during testing, achieving strong fixation without overly complex mechanisms.
Data Source
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AI summary
Provided is a test jig including a jig main body having, at an end portion thereof, an insertion part into which an electrode lead is inserted and a fixing member detachably coupled to the insertion part to fix the electrode lead inserted to the insertion part, wherein the insertion part includes insertion faces outwardly extending from both end portions of the jig main body, and coupling faces extending from the insertion faces toward insides of the jig main body and brought into contact with the fixing member, and thus a tensile test is performed on an ultrasonic-welded portion of the electrode lead without an additional cell.