Zigzag Electrode Tabs for Ultrasonic Welding Vibration Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery module welding methods, such as laser welding, face challenges in mass production due to limited spot size and difficulty in welding multiple tabs in parallel structures, leading to potential damage from ultrasonic wave vibrations during the welding process.
Innovation Solution
A battery module design featuring electrode tabs with zigzag extensions that absorb vibrations by bending upward and downward, allowing for ultrasonic wave welding without damaging the battery cells, and an ultrasonic wave welding method that forms a welding surface parallel to the battery cell using extensions and adhering members like rollers or springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic wave welding is used to weld electrode tabs in parallel with battery cells, then mass production efficiency is improved compared to laser welding, but vibrations during welding may damage the battery cell
Solution Approach 1:
A vibration-absorbing member is introduced as an intermediary component between the ultrasonic wave welding device and the battery cell. This mediator absorbs the harmful vibrations generated during ultrasonic welding, allowing the welding process to proceed efficiently while protecting the battery cell from vibration damage.
Solution Approach 2:
The vibration-absorbing member converts the harmful vibrations into a beneficial function by dissipating them through controlled deformation or energy absorption. The member is designed to deform elastically or plastically under vibration, transforming the harmful mechanical energy into heat or other harmless forms, thus protecting the battery cell while maintaining welding effectiveness.
2Manufacturing precision
If laser welding is used with a spot size of about 230μm, then precise welding is achieved, but the limited spot size greatly degrades mass production during module assembling
Solution Approach 1:
The patent replaces laser welding with ultrasonic wave welding. Ultrasonic welding uses mechanical vibrations at high frequency to join materials, eliminating the need for a focused laser beam. This substitution allows for larger welding areas and simultaneous welding of multiple tabs, significantly improving mass production efficiency while maintaining adequate welding precision through the mechanical action of ultrasonic vibrations.
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
The zigzag design effectively minimizes damage from ultrasonic wave vibrations while simplifying the manufacturing process, enabling higher mass production efficiency compared to laser welding.
Implementation Method 1
fused by ultrasonic wave vibrations
Implementation Method 2
absorb vibrations even when a welding portion formed in parallel with a battery cell is fused by ultrasonic wave vibrations
Data Source
Figure 1~2
Figure 3~4(b)
Figure 5~6
AI summary
Provided are a battery module and an electrode tab ultrasonic wave welding method. The present invention relates to a battery module and an electrode tab ultrasonic wave welding method by forming the electrode tab in a zigzag form in which the electrode tab extending upwardly is bent downwardly and then, again bent upwardly to allow the electrode tab formed in the zigzag form to absorb vibrations even when a welding portion formed in parallel with a battery cell is fused by ultrasonic wave vibrations, thereby minimizing damage to the battery cell.