Textured Composite Metal Foil Bonding for Pouch Cell Pre-Sealing
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Solution Overview
Problem
Current methods for connecting pre-sealing tapes to composite metal foils in pouch cells are inefficient, requiring laborious cooling during welding, limiting welding methods, and resulting in high electric resistance and increased production costs due to the need for prefabricated arrester tabs with pre-sealing tapes.
Innovation Solution
A method involving creating a texture on the composite metal foil, applying and connecting a pre-sealing tape to form a composite body, and cutting it to size, which allows for secure adhesion and the use of pressure welding, eliminating the need for continuous cooling and prefabricated arrester tabs, and reducing ohmic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect arrester tabs to electrodes, then electrical connection is achieved, but heat input damages the temperature-sensitive pre-sealing tapes
Solution Approach 1:
The pre-sealing tape is separated from the arrester tab and attached to the composite metal foil instead, dividing the system into independent components that can be processed separately without mutual interference
Solution Approach 2:
The pre-sealing tape is extracted from the arrester tab assembly and repositioned to the composite metal foil, removing it from the welding zone to prevent heat damage while maintaining its sealing function
2Object-affected harmful factors
If continuous cooling is applied during welding to protect pre-sealing tapes, then heat damage is prevented, but production complexity and labor requirements increase
Solution Approach 1:
The pre-sealing tape is removed from the welding zone entirely by repositioning it to the composite metal foil, eliminating the need for cooling systems and complex heat management procedures
Solution Approach 2:
The manufacturing process is segmented into separate operations: welding the arrester tab to the electrode first, then separately attaching the pre-sealing tape to the composite metal foil, avoiding the need for simultaneous cooling during welding
3Object-affected harmful factors
If large distance is maintained between weld and pre-sealing tape to avoid heat input, then heat damage is prevented, but installation space is lost
Solution Approach 1:
Instead of maintaining distance between the weld and pre-sealing tape on the same component, the pre-sealing tape is repositioned to the opposite side (composite metal foil), allowing close proximity without heat interference
Solution Approach 2:
The pre-sealing tape is extracted from the heat-affected zone near the weld and repositioned to the composite metal foil, maximizing space utilization while preventing heat damage
4Object-affected harmful factors
If only spot welding or resistance welding is used for arrester tabs, then pre-sealing tapes are protected from damage, but electrical resistance increases
Solution Approach 1:
The system is divided into two independent connection points: arrester tab to electrode (welding) and pre-sealing tape to composite metal foil (adhesive bonding), allowing optimization of each connection type for its specific function
Solution Approach 2:
The composite metal foil acts as an intermediary carrier for the pre-sealing tape, separating it from the electrical connection path and allowing superior welding methods to be used for the electrical connection without compromising the pre-sealing tape
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 method simplifies the production process, reduces electric resistance, and lowers production costs by enabling secure connection of pre-sealing tapes to the composite metal foil, allowing for more efficient and cost-effective manufacturing of pouch cells with improved electric properties.
Implementation Method 1
creating a texture in at least a partial area of the composite metal foil... connecting the pre-sealing tape to the composite metal foil to form a composite body
Implementation Method 2
The use of surface welding (also known as pressure welding) is not possible since this would cause damage to the pre-sealing tapes... allowing for pressure welding, eliminating the need for continuous cooling
Data Source
AI summary
A method for connecting a pre-sealing tape to a composite metal foil for pouch cells comprises at least the following steps: (a) creating a texture in at least a partial area of the composite metal foil; (b) applying a pre-sealing tape onto the composite metal foil, whereby the texture is at least partially covered by the pre-sealing tape; (c) connecting the pre-sealing tape to the composite metal foil to form a composite body; and (d) cutting the composite body to the predefined finished contour.