Electrode assembly for secondary battery and method of manufacturing electrode assembly

Abstract

This disclosure relates to a method for manufacturing electrode assemblies for secondary batteries that can simultaneously improve the accuracy and speed of stacking processes, and to electrode assemblies manufactured using this method. The method includes: preparing current collectors; cutting the current collectors into a predetermined pattern; and stacking the cut current collectors.

Description

Cross-reference to related applications

[0001] This application claims priority and benefit to Korean Patent Application No. 10-2025-0017034, filed on February 11, 2025, with the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] Embodiments of this disclosure relate to electrode assemblies for secondary batteries and methods of manufacturing electrode assemblies. Background Technology

[0003] Unlike primary batteries, which are not designed for recharging, secondary (also known as rechargeable) batteries are designed to be discharged and recharged. Low-capacity secondary batteries are widely used in portable small electronic devices such as smartphones, feature phones, laptops, digital cameras, and camcorders, while high-capacity secondary batteries are widely used as power sources for driving motors in hybrid and electric vehicles, as well as for storing electricity (e.g., household and / or utility-scale power storage). A secondary battery typically includes an electrode assembly containing positive and negative electrodes, a housing that houses the electrode assembly, and electrode terminals connected to the electrode assembly.

[0004] This background section is intended for a general understanding of the background of this disclosure, and therefore may contain information that does not constitute related (or prior art). Summary of the Invention

[0005] Embodiments of this disclosure provide a method for manufacturing electrode assemblies for secondary batteries that can simultaneously improve the accuracy and speed of the stacking process. Embodiments of this disclosure also provide an electrode assembly manufactured using this method.

[0006] These and other aspects and features of this disclosure will be described in or will become apparent from the following description of embodiments of this disclosure.

[0007] A method for manufacturing an electrode assembly for a secondary battery according to embodiments of the present disclosure includes: a conveying step of preparing a current collector, the current collector being configured such that a first separator is inserted between a first electrode plate and a second electrode plate, a second separator is provided on a surface of the first electrode plate or the second electrode plate, and the first electrode plate, the first separator, the second electrode plate, and the second separator are integrally stacked; a punching step of cutting the current collector into a predetermined pattern; and a stacking step of stacking the cut current collector, wherein the first electrode plate includes: a first electrode active material layer configured to cover at least one surface of a first electrode current collector made of a plate-shaped metal foil; and a first The first electrode uncoated portion is not coated with the first electrode active material layer; the second electrode plate includes a second electrode active material layer and is configured to cover at least one surface of a second electrode current collector made of a plate-shaped metal foil; and the second electrode uncoated portion is not coated with the second electrode active material layer; the first electrode plate and the second electrode plate are configured such that the first electrode uncoated portion and the second electrode uncoated portion do not overlap each other; and the punching step includes simultaneously cutting the first electrode active material layer, the first electrode uncoated portion, the second electrode active layer, and the second electrode uncoated portion.

[0008] Embodiments of this disclosure provide a method for manufacturing an electrode assembly for a secondary battery. The method includes: preparing a current collector assembly, wherein a first separator is inserted between a first electrode plate and a second electrode plate, wherein a second separator is provided on a surface of the first electrode plate or a surface of the second electrode plate, and wherein the first electrode plate, the first separator, the second electrode plate, and the second separator are stacked; cutting the current collector assembly into a predetermined pattern; and stacking the cut current collector assembly, wherein the first electrode plate includes a first electrode active material layer and a first electrode uncoated portion, the first electrode active material layer including a first electrode active material and covering at least one surface of the first electrode current collector, the first electrode uncoated portion not coated with the first electrode active material, wherein the second electrode plate includes a second electrode active material layer and a second electrode uncoated portion, the second electrode active material layer including a second electrode active material and covering at least one surface of the second electrode current collector, the second electrode uncoated portion not coated with the second electrode active material, wherein the first electrode uncoated portion and the second electrode uncoated portion do not overlap each other, and wherein in the cutting, the first electrode active material layer, the first electrode uncoated portion, the second electrode active material layer, and the second electrode uncoated portion are cut substantially simultaneously.

[0009] In some embodiments, the uncoated portion of the first electrode may extend in a first direction which is the longitudinal direction of the current collector group, and may be positioned on one side in a second direction which is the transverse direction of the current collector group, and the uncoated portion of the second electrode may extend in the first direction and may be positioned on the other side in the second direction.

[0010] In some embodiments, the uncoated portion of the first electrode may extend in the longitudinal direction of the current collector and be located on one side in the transverse direction of the current collector, and wherein the uncoated portion of the second electrode may extend in the longitudinal direction and be located on the other side in the transverse direction.

[0011] In some embodiments, the current collector may be configured such that the uncoated portion of the first electrode is exposed on one side in the second direction, and the uncoated portion of the second electrode is exposed on the other side in the second direction.

[0012] In some embodiments, the uncoated portion of the first electrode is exposed on one side, and the uncoated portion of the second electrode is exposed on the other side.

[0013] In some embodiments, the punching step may include cutting the current collector into a pattern, the pattern including: a main region corresponding to the first electrode active material layer; and protruding regions protruding from the main region toward each of the other side in the second direction.

[0014] In some embodiments, the predetermined pattern includes: a main region corresponding to the first electrode active material layer; and protruding regions protruding from the main region to each of the other side.

[0015] In some embodiments, the punching step may include cutting the current collector into a pattern, wherein individual segments are arranged sequentially in the first direction, which is the longitudinal direction, and each individual segment includes: a main region corresponding to the first electrode active material layer; and a protruding region protruding from the main region to each of the other side in the second direction.

[0016] In some embodiments, the predetermined pattern includes independent segments arranged sequentially in the longitudinal direction, each independent segment including: a main region corresponding to the first electrode active material layer; and a protruding region protruding from the main region to each of the other side.

[0017] In some embodiments, the punching step may include cutting the current collector using at least one of a die frame and a laser.

[0018] In some embodiments, the cutting is performed using a mold or a laser.

[0019] In some embodiments, the area of ​​the first electrode active material layer may be smaller than the area of ​​the second electrode active material layer.

[0020] In some embodiments, the area of ​​each of the first diaphragm and the second diaphragm may be greater than the area of ​​each of the first electrode active material layer and the second electrode active material layer.

[0021] In some embodiments, the method may further include: in the transfer step, using a fixing member to fix at least a portion of the current collection group; and in the stacking step, removing the fixing member.

[0022] In some embodiments, during the fabrication, at least a portion of the current collector is secured using a fixing member, and the fixing member is removed during the stacking process.

[0023] In some embodiments, the first electrode plate may have first uncoated portions extending from one side in the second direction and spaced at regular intervals, and the punching step may include cutting at least a portion of each of the first uncoated portions extending in the second direction.

[0024] In some embodiments, the first electrode uncoated portion of the first electrode plate has a plurality of first electrode uncoated portions extending from the side and spaced apart at regular intervals, and wherein, during the cutting, at least a portion of each of the plurality of first electrode uncoated portions extends in the lateral direction.

[0025] In some embodiments, the first electrode plate may be configured such that the uncoated portion of the first electrode extends in the first direction at the center of the first electrode plate in the second direction, and the second electrode plate may include: a first column of electrode plates configured such that the uncoated portion of the second electrode of the first column of electrode plates extends in the first direction and is located on one side in the second direction; and a second column of electrode plates configured such that the uncoated portion of the second electrode of the second column of electrode plates extends in the first direction and is located on the other side in the second direction, wherein the uncoated portion of the second electrode of the second electrode plate includes the uncoated portion of the second electrode of the first column of electrode plates and the uncoated portion of the second electrode of the second column of electrode plates.

[0026] In some embodiments, the first uncoated portion of the electrode extends in the longitudinal direction at the center of the first electrode plate in the lateral direction, and the second electrode plate includes: a first column of electrode plates having a second uncoated portion of the electrode extending in the longitudinal direction and located on one side; and a second column of electrode plates having a second uncoated portion of the electrode extending in the longitudinal direction and located on the other side, wherein the second uncoated portion of the second electrode plate includes the second uncoated portion of the first column of electrode plates and the second uncoated portion of the second column of electrode plates.

[0027] In some embodiments, the current collector may be configured such that the uncoated portion of the second electrode is exposed on each of the one side and the other side in the second direction, and the uncoated portion of the first electrode is formed along its centerline.

[0028] In some embodiments, the uncoated portion of the second electrode is exposed on each of the one side and the other side, and the uncoated portion of the first electrode is exposed along the centerline of the current collector.

[0029] In some embodiments, the punching step may include cutting the current collector into a pattern, the pattern including: a main region corresponding to the first electrode active material layer; and a protruding region protruding from the main region in a direction toward each of the uncoated portion of the first electrode and the uncoated portion of the second electrode of the first column of electrode plates.

[0030] In some embodiments, the predetermined pattern includes: a main region corresponding to the first electrode active material layer; and a protruding region protruding from the main region in a direction toward each of the uncoated portion of the first electrode and the uncoated portion of the second electrode of the first column of electrode plates.

[0031] In some embodiments, the punching step may include cutting the current collector into a pattern, the pattern including: a main region corresponding to the first electrode active material layer; and a protruding region protruding from the main region in a direction toward each of the uncoated portions of the first electrode and the uncoated portions of the second electrode in the second column of electrode plates.

[0032] In some embodiments, the predetermined pattern includes: a main region corresponding to the first electrode active material layer; and a protruding region protruding from the main region in a direction toward each of the uncoated portions of the first electrode and the uncoated portions of the second electrode in the second column of electrode plates.

[0033] In some embodiments, the punching step may include cutting the current collector into a pattern, wherein individual segments are arranged sequentially in the second direction relative to the uncoated portion of the first electrode, each individual segment including: a main region corresponding to the active material layer of the first electrode; and a protruding region protruding from the main region toward each of the other side in the second direction.

[0034] In some embodiments, the predetermined pattern includes independent segments arranged sequentially in the lateral direction relative to the uncoated portion of the first electrode, each independent segment including: a main region corresponding to the active material layer of the first electrode; and a protruding region protruding from the main region to each of the other side.

[0035] In some embodiments, the pattern in which the individual segments are arranged sequentially in the second direction can be configured such that the protruding regions located at the uncoated portions of the first electrode engage with each other.

[0036] In some embodiments, the plurality of protruding regions located on the uncoated portion of the first electrode engage with each other.

[0037] In some embodiments, the method may further include: a step of stacking a plurality of the current collectors to provide the plurality of current collectors, such as at least two current collectors; and a punching step of cutting the stacked plurality of current collectors into a predetermined pattern.

[0038] In some embodiments, the method further includes cutting the stacked plurality of current collectors into another predetermined pattern.

[0039] In some embodiments, the stacking step may include sequentially stacking the second electrode plate, the first diaphragm, the first electrode plate and the second diaphragm, or sequentially stacking the second diaphragm, the second electrode plate, the first diaphragm and the first electrode plate.

[0040] In some embodiments, the second electrode plate, the first diaphragm, the first electrode plate and the second diaphragm are stacked sequentially, or wherein the second diaphragm, the second electrode plate, the first diaphragm and the first electrode plate are stacked sequentially.

[0041] An electrode assembly for a secondary battery manufactured using a method for manufacturing an electrode assembly for a secondary battery according to an embodiment of the present disclosure to achieve the above-described objectives includes: a first electrode plate having a first electrode uncoated portion, a portion of which is punched, the first electrode uncoated portion extending to one side and protruding; and a second electrode plate having a second electrode uncoated portion, a portion of which is punched, the second electrode uncoated portion extending to and protruding to the opposite side, wherein the first electrode plate is configured as a plurality of first electrode plates, the second electrode plate is configured as a plurality of second electrode plates, and the plurality of first electrode plates and the plurality of second electrode plates are stacked with a plurality of separators between them.

[0042] Embodiments of this disclosure provide an electrode assembly for a secondary battery, the electrode assembly comprising: a plurality of first electrode plates, each having a first electrode uncoated portion, a portion of the first electrode uncoated portion being punched out, the first electrode uncoated portion extending to one side and protruding; and a plurality of second electrode plates, each having a second electrode uncoated portion, a portion of the second electrode uncoated portion being punched out, the second electrode uncoated portion extending to an opposite side and protruding, wherein a separator is located between each of the plurality of first electrode plates and each of the plurality of second electrode plates.

[0043] In some embodiments, the corners on both sides of each of the uncoated portions of the first and second electrodes may be punched, or the uncoated portions of the first and second electrodes may protrude asymmetrically.

[0044] In some embodiments, the corners on both sides of each of the uncoated portions of the first and second electrodes are punched, or each of the uncoated portions of the first and second electrodes protrudes asymmetrically outward. Attached Figure Description

[0045] The accompanying drawings illustrate embodiments of the present disclosure and, together with the detailed description of the present disclosure, further describe various aspects and features of the present disclosure. Therefore, the present disclosure should not be construed as limited to the drawings:

[0046] Figure 1 This is a perspective view of a stacking apparatus for manufacturing secondary batteries according to various embodiments of the present disclosure;

[0047] Figure 2 This is a perspective view showing an electrode assembly for a secondary battery according to various embodiments of the present disclosure;

[0048] Figure 3 Various embodiments according to this disclosure Figure 2 An exploded perspective view of the current collector of the electrode assembly shown in the figure;

[0049] Figure 4 This is an exploded perspective view of a current collector assembly comprising a dual-coated electrode plate according to various embodiments of the present disclosure.

[0050] Figure 5 This is an exploded perspective view of a current collector assembly comprising a patterned electrode plate according to various embodiments of the present disclosure.

[0051] Figure 6 Various embodiments according to this disclosure Figure 2 A plan view of the electrode assembly shown in the figure;

[0052] Figure 7 Various embodiments according to this disclosure Figure 4 A plan view of the electrode assembly shown in the figure;

[0053] Figure 8 This is a perspective view illustrating various embodiments of a secondary battery according to the present disclosure;

[0054] Figure 9 It is according to various embodiments of this disclosure along Figure 8 A cross-sectional view taken from line II-II in the diagram;

[0055] Figure 10 This is a perspective view illustrating various embodiments of a battery module according to the present disclosure;

[0056] Figure 11 Battery packs according to various embodiments of the present disclosure are shown;

[0057] Figure 12 Battery packs according to various embodiments of the present disclosure are shown;

[0058] Figure 13 This illustration shows vehicle body and vehicle components having battery packs according to various embodiments of the present disclosure; and

[0059] Figure 14 The diagram shows a vehicle body and vehicle components having battery packs according to various embodiments of the present disclosure. Detailed Implementation

[0060] Embodiments of this disclosure are described in detail with reference to the accompanying drawings. The terms or words used in this specification and claims should not be construed as having a general or dictionary meaning, but should be interpreted in a way consistent with the technical spirit of this disclosure, based on the principle that the inventor is capable of being his / her own lexicographer to appropriately define the concepts of the terms and to best describe his / her invention.

[0061] Therefore, the embodiments described in this specification and the configurations shown in the accompanying drawings are merely some embodiments of this disclosure and do not represent all the technical spirit, aspects, and features of this disclosure. Accordingly, it should be understood that various equivalents and modifications that can replace or modify the embodiments described herein may exist at the time of filing this application.

[0062] Additionally, it will be understood that the terms “comprising” and / or “including” as used in this specification specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Furthermore, when describing embodiments of this disclosure, the wording “may” or “may be” may include “one or more embodiments of this disclosure”.

[0063] Additionally, for better understanding of the invention, the drawings are not drawn to scale, and the dimensions of some parts may be exaggerated. Furthermore, the same reference numerals may be assigned to the same parts in different embodiments. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Furthermore, when describing embodiments of this disclosure, the use of "may" refers to "one or more embodiments of this disclosure." Expressions such as "at least one of..." and "any one of..." modify the entire list of elements when following it, not individual elements in the list. When phrases such as "at least one of A, B, and C," "at least one of A, B, or C," "at least one selected from the group of A, B, and C," or "at least one selected from A, B, and C" are used to refer to a list of elements A, B, and C, the phrase may refer to any one of A, B, and C and all suitable combinations or subsets of them, such as A, B, C, A and B, A and C, B and C, or A and B and C. As used herein, the term "use" may be considered synonymous with the term "utilize." As used herein, the terms “substantially,” “about,” and similar terms are used as approximate terms and not as terms of degree, and are intended to describe the inherent variations in measured or calculated values ​​that would be recognized by one of ordinary skill in the art.

[0064] Referring to two compared objects as “identical” means that they are “substantially identical.” Therefore, the phrase “substantially identical” can include cases where the deviation is considered low in the relevant technique (e.g., within 5%). Additionally, when either parameter is described as consistent over a given region, it can mean that the parameter is consistent on an average basis.

[0065] It will be understood that although the terms “first,” “second,” etc., may be used herein to describe various components, these components should not be limited by these terms. These terms are used to distinguish one component from another. Therefore, unless otherwise defined, the first component described below may be referred to as the second component without departing from the spirit and scope of this disclosure.

[0066] Throughout this specification, unless the context clearly indicates otherwise, the singular form is intended to include the plural form as well.

[0067] For ease of description, spatial relative terms such as “below,” “under,” “down,” “above,” and “above” are used herein to describe the relationship between one element or feature illustrated in the figure and another element or feature. It will be understood that spatial relative terms are intended to cover different orientations of the device in use or operation other than those depicted in the figure. For example, if the device in the figure is flipped, an element described as “below” or “under” other elements or features would then be oriented as “above” or “above” other elements or features. Therefore, the term “below” can encompass both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptive terms used herein should be interpreted accordingly.

[0068] Arranging any component on the "upper part (or lower part)" or "upper (or lower) part" of a component means that the arbitrary component is placed in contact with the upper (or lower) surface of the component. Additionally, it can mean that other components may be located between the component and the arbitrary component disposed on (or below) the component.

[0069] The terminology used herein is for the purpose of describing embodiments of this disclosure and is not intended to limit this disclosure. Unless the context clearly indicates otherwise, the singular form “a” as used herein is intended to include the plural form as well. It will be further understood that the terms “comprising” and / or “including” as used in this specification specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0070] Furthermore, any numerical range disclosed and / or described herein is intended to include all subranges with the same numerical precision contained within the described range. For example, the range "1.0 to 10.0" is intended to include all subranges between the described minimum value of 1.0 and the described maximum value of 10.0 (and including both the described minimum value of 1.0 and the described maximum value of 10.0), i.e., a minimum value equal to or greater than 1.0 and a maximum value equal to or less than 10.0, such as 2.4 to 7.6. Any maximum numerical limit described herein is intended to include all lower numerical limits contained therein, and any minimum numerical limit described herein is intended to include all higher numerical limits contained therein. Accordingly, the applicant reserves the right to amend this specification, including the claims, to explicitly describe any subranges contained within the range explicitly described herein. All such ranges are intended to be inherently described in this specification such that any modification to explicitly describe any such subrange will comply with the applicable requirements.

[0071] Furthermore, it will be understood that when an element is referred to as "connected to," "linked to," or "attached to" another element, these elements may be directly connected or linked to each other, with another intermediary element between them, or the elements may be connected, linked, or linked to each other through another element. Additionally, it will be understood that when an element is referred to as being electrically connected to another element, the element may be directly connected to the other element, or with an intermediary element between them, such that the element and the other element are indirectly connected to each other.

[0072] Throughout this specification, unless otherwise stated, each element may be singular or plural.

[0073] Arranging any element "above (or below)" or "above (or below)" another element can mean that the arbitrary element can be configured to contact the upper (or lower) surface of the element, and the other element can be located between the element and the arbitrary element disposed on (or below) the element.

[0074] Throughout this specification, unless otherwise stated, the phrase "A and / or B" means A, B, or A and B. That is, "and / or" includes any one or all of the listed items. Unless otherwise stated, the phrase "C~D" means C and below D.

[0075] Figure 1 This is a perspective view of a stacking device 1 used to manufacture secondary batteries.

[0076] like Figure 1 As shown, the stacking device 1 may include a first electrode plate supply unit 1100, a first diaphragm supply unit 1200, a second diaphragm supply unit 1300, and a second electrode plate supply unit 1400.

[0077] The first electrode plate supply unit 1100 may include a first electrode plate supply roller. A first electrode plate 111 may be wound around the first electrode plate supply roller. As the first electrode plate supply roller rotates, the first electrode plate 111 can be unwound and supplied. Therefore, the first electrode plate 111 can be supplied continuously.

[0078] The first diaphragm supply unit 1200 may include a first diaphragm supply roller. A first diaphragm 1131 may be wound on the first diaphragm supply roller. As the first diaphragm supply roller rotates, the first diaphragm 1131 can be unwound and supplied. Therefore, the first diaphragm 1131 can be continuously supplied and stacked.

[0079] The second diaphragm supply unit 1300 may include a second diaphragm supply roller. A second diaphragm 1132 may be wound around the second diaphragm supply roller. As the second diaphragm supply roller rotates, the second diaphragm 1132 can be unwound and supplied. Therefore, the second diaphragms 1132 can be continuously supplied and stacked. In some embodiments, the first diaphragm 1131 and the second diaphragm 1132 may be implemented substantially identically and may be collectively referred to as diaphragms below.

[0080] The second electrode plate supply unit 1400 may include a second electrode plate supply roller. The second electrode plate 112 may be wound around the second electrode plate supply roller. As the second electrode plate supply roller rotates, the second electrode plate 112 can be unwound and supplied. Therefore, the second electrode plate 112 can be supplied continuously.

[0081] The stacking device 1 may further include a first guide roller 1500 and a second guide roller 1600. A first electrode plate 111, a first diaphragm 1131, a second diaphragm 1132, and a second electrode plate 112, supplied from a first electrode plate supply unit 1100, a first diaphragm supply unit 1200, a second diaphragm supply unit 1300, and a second electrode plate supply unit 1400, respectively, can be inserted between the first guide roller 1500 and the second guide roller 1600. In some embodiments, between the first guide roller 1500 and the second guide roller 1600, the second diaphragm 1132, the second electrode plate 112, the first diaphragm 1131, and the first electrode plate 111 can be sequentially arranged and stacked from the bottom to form a current collector group 110S. As the first guide roller 1500 and the second guide roller 1600 rotate, the current collector group 110S can be conveyed to the stacking unit 1800.

[0082] In some embodiments, between the first guide roller 1500 and the second guide roller 1600, the second electrode plate 112, the first diaphragm 1131, the first electrode plate 111 and the second diaphragm 1132 can be sequentially arranged and stacked from the bottom to form a current collector group 110S. In some embodiments, multiple diaphragms can be provided between multiple first electrode plates 111 and multiple second electrode plates 112.

[0083] In some embodiments, the stacking device 1 may further include a punching unit 1700 configured to cut the current collector group 110S in a predetermined pattern. The punching unit 1700 may use at least one of a die and a laser to cut the current collector group 110S.

[0084] In some embodiments, the stacking device 1 may further include a pick-and-place device (not shown). The pick-and-place device can convey current collectors 110S cut in a predetermined pattern to the stacking unit 1800. If the predetermined pattern is an array of multiple patterns, several current collectors can be cut at once. The multiple current collectors can be stacked sequentially on the stacking unit 1800.

[0085] Multiple current collectors can be stacked on stacking unit 1800. The stacked current collectors can form electrode assembly 110. Electrode assembly 110 can be configured such that a first electrode plate 111 and a second electrode plate 112 are stacked with a diaphragm between them.

[0086] In some embodiments, the stacking device 1 may further include a fixing unit having a fixing member configured to fix a portion of each of the current collectors 110S before they reach the punching unit 1700, such that the current collectors 110S can be aligned and fixed when punched while they are stacked. For example, a clamp or tweezers can be used to pick up the unfolded current collectors in the stacked state for movement together in the direction of travel. Even after punching, the current collectors can be moved in the picked-up state, maintaining their fixed state until they are conveyed to the stacking unit 1800, after which the fixing member can be removed. When punching the current collectors 110S, the corners of the current collectors can be partially punched, allowing the current collectors to be aligned and fixed based on the partially punched portions.

[0087] Figure 2 This is a perspective view showing the electrode assembly 110 for a secondary battery.

[0088] like Figure 2As shown, the electrode assembly 110 may include a first electrode plate 111, a second electrode plate 112, and a diaphragm 113 disposed between the first electrode plate 111 and the second electrode plate 112, which are stacked in sequence. The electrode assembly 110 may have a cuboid structure, wherein the first electrode plate 111, the plate-shaped diaphragm 113, and the second electrode plate 112 are stacked in sequence.

[0089] Electrode assembly 110 may include a first electrode plate 111, a second electrode plate 112, and a diaphragm 113 between the first electrode plate 111 and the second electrode plate 112. In some examples, electrode assembly 110 may be formed by stacking the first electrode plate 111, the diaphragm 113, and the second electrode plate 112, each of which may be formed in a plate shape or a thin film shape. In some embodiments, electrode assembly 110 may be formed by stacking one or more electrode assemblies 110 together or adjacent to each other, and the number of electrode assemblies 110 is not limited in this invention. In some embodiments, the first electrode plate 111 may act as a positive electrode, and the second electrode plate 112 may act as a negative electrode. In some embodiments, the first electrode plate 111 may act as a negative electrode, and the second electrode plate 112 may act as a positive electrode.

[0090] The first electrode plate 111 can be formed by coating a first electrode active material (such as a transition metal oxide) onto a first electrode current collector (first electrode current collector) made of a metal foil including aluminum or an aluminum alloy. The first electrode plate 111 may include a first electrode active material layer 111b having the first electrode active material coated thereon. The first electrode plate 111 may include a first electrode uncoated portion 111a, which is an area where the first electrode active material is not coated.

[0091] In some embodiments, the uncoated portion 111a of the first electrode may be a first electrode tab 114. The first electrode tab 114 may be referred to as a substrate tab. The first electrode tab 114 may be formed by pre-cutting the first electrode plate 111 during the manufacture of the first electrode plate 111 so that the first electrode tab 114 protrudes to one side, or it may protrude to one side from the diaphragm 113 without cutting.

[0092] The positive electrode active material (i.e., the first active material) may include compounds capable of reversibly inserting / deintercalating lithium (lithiation intercalation compounds). For example, a composite oxide of lithium with metals including cobalt, manganese, nickel, or combinations thereof may be used.

[0093] The composite oxide may include lithium transition metal composite oxides, and non-limiting examples may include lithium nickel-based oxides, lithium cobalt-based oxides, lithium manganese-based oxides, lithium iron phosphate-based compounds, cobalt-free nickel manganese-based oxides, or combinations thereof.

[0094] For example, compounds represented by any of the following chemical formulas can be used: Li a A 1-b X b O 2-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Mn 2-b X b O 4-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Ni 1-b-c Co b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni 1-b- c Mn b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni b Co c L 1 d G e O2 (0.90≤a≤1.8, 0≤b≤0.9, 0≤c≤0.5, 0≤d≤0.5, 0≤e≤0.1); Li a NiG b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a CoG b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-b G b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn2G b O4(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-gG g PO4(0.90≤a≤1.8, 0≤g≤0.5); Li (3-f) Fe2(PO4)3 (0≤f≤2); and Li a FePO4 (0.90≤a≤1.8).

[0095] In the above chemical formulas: A is Ni, Co, Mn, or a combination thereof; X is Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V, rare earth elements, or a combination thereof; D is O, F, S, P, or a combination thereof; G is Al, Cr, Mn, Fe, Mg, La, Ce, Sr, V, or a combination thereof; and L 1 It is Mn, Al, or a combination thereof.

[0096] The positive electrode for a lithium secondary battery may include a current collector and a layer of positive electrode active material formed on the current collector. The positive electrode active material layer may include a positive electrode active material and may include a binder and / or a conductive material.

[0097] Based on a 100 wt% positive electrode active material layer, the content of the positive electrode active material is in the range of about 90 wt% to about 99.5 wt%, and based on the 100 wt% positive electrode active material layer, the contents of the binder and conductive material are in the range of about 0.5 wt% to about 5 wt%, respectively.

[0098] Aluminum (Al) can be used as a current collector, but it is not limited to this.

[0099] The second electrode plate 112 can be formed by coating a second electrode active material (such as graphite or carbon) onto a second electrode current collector (second electrode current collector) made of a metal foil including copper, copper alloy, nickel, or nickel alloy. The second electrode plate 112 may include a second electrode active material layer 112b having the second electrode active material coated thereon. The second electrode plate 112 may include an uncoated portion 112a, which is the area where the second electrode active material is not coated.

[0100] In some embodiments, the uncoated portion 112a of the second electrode may be a second electrode tab 115. The second electrode tab 115 may be referred to as a substrate tab. The second electrode tab 115 may be formed by pre-cutting the second electrode plate 112 during the manufacture of the second electrode plate 112 so that the second electrode tab 115 protrudes to the other side, or it may protrude to the other side of the diaphragm 113 without cutting.

[0101] The negative electrode active material (i.e., the second active material) may include a material capable of reversibly intercalating / deintercalating lithium ions, lithium metal, an alloy of lithium metal, a material capable of doping and dedoping lithium, or a transition metal oxide.

[0102] The material capable of reversibly intercalating / deintercalating lithium ions may include a carbon-based negative electrode active material, which may include, for example, crystalline carbon, amorphous carbon, or a combination thereof. Non-limiting examples of crystalline carbon may include graphite, such as natural graphite or artificial graphite, and non-limiting examples of amorphous carbon may include soft carbon, hard carbon, pitch carbide, mesophase pitch carbide, calcined coke, etc.

[0103] The Si-based negative electrode active material or the Sn-based negative electrode active material may be used as the material capable of doping and dedoping lithium. The Si-based negative electrode active material may include silicon, a silicon-carbon composite, SiO x (0 < x ≤ 2), a Si-based alloy, or a combination thereof.

[0104] The silicon-carbon composite may include a composite of silicon and amorphous carbon. In some embodiments, the silicon-carbon composite may be in the form of silicon particles and amorphous carbon coated on the surface of the silicon particles.

[0105] The silicon-carbon composite may include crystalline carbon. For example, the silicon-carbon composite may include a core containing crystalline carbon and silicon particles and an amorphous carbon coating on the surface of the core.

[0106] The negative electrode for a lithium secondary battery may include a current collector and a negative electrode active material layer provided on the current collector. The negative electrode active material layer may include a negative electrode active material and may further include a binder and / or a conductive material.

[0107] For example, the negative electrode active material layer may include about 90 wt% to about 99 wt% of the negative electrode active material, about 0.5 wt% to about 5 wt% of the binder, and about 0 wt% to about 5 wt% of the conductive material.

[0108] A non-aqueous binder, an aqueous binder, a dry binder, or a combination thereof may be used as the binder. When an aqueous binder is used as the negative electrode binder, it may include a cellulose-based compound capable of imparting viscosity.

[0109] The negative electrode current collector may include a copper foil, a nickel foil, a stainless steel foil, a titanium foil, a nickel foam, a copper foam, a polymer substrate coated with a conductive metal, or a combination thereof.

[0110] The electrolyte for a lithium secondary battery may include a non-aqueous organic solvent and a lithium salt.

[0111] The non-aqueous organic solvent serves as a medium through which ions participating in the electrochemical reaction of the battery can migrate.

[0112] Non-aqueous organic solvents may include carbonate solvents, ester solvents, ether solvents, ketone solvents, alcohol solvents, and aprotic solvents, and may be used alone or in combination of two or more.

[0113] When using carbonate solvents, a mixture of cyclic carbonates and chain carbonates can be used.

[0114] A separator 113 may be disposed between the first electrode plate 111 and the second electrode plate 112 to prevent electrical short circuits that may occur between the first electrode plate 111 and the second electrode plate 112. Separators 113 may be provided in pairs, and the first electrode plate 111 may be assembled between the pair of separators 113. Separators 113 may be disposed between the first electrode plate 111 and the second electrode plate 112 to prevent electrical short circuits and allow lithium-ion migration. In some embodiments, the separator 113 may be located on the outermost side of the electrode assembly 110. The separator 113 may be located on the long side surface 110z of the electrode assembly 110. However, this disclosure is not limited thereto.

[0115] Depending on the type of lithium-ion secondary battery, a separator can be present between the positive and negative electrodes. The separator can include polyethylene, polypropylene, polyvinylidene fluoride, or a multilayer film of two or more layers thereof.

[0116] The diaphragm 113 may include a porous substrate and a coating on one or both surfaces of the porous substrate, comprising organic materials, inorganic materials or combinations thereof.

[0117] Organic materials may include polyvinylidene fluoride polymers or (meth)acrylic acid polymers.

[0118] Inorganic materials may include, but are not limited to, inorganic particles selected from Al2O3, SiO2, TiO2, SnO2, CeO2, MgO, NiO, CaO, GaO, ZnO, ZrO2, Y2O3, SrTiO3, BaTiO3, Mg(OH)2, boehmite and combinations thereof.

[0119] Organic and inorganic materials can be mixed in a single coating, or they can be in the form of coatings containing organic materials and coatings containing inorganic materials layered on top of each other.

[0120] Figure 3 yes Figure 2 An exploded perspective view of the current collector 110S of the electrode assembly 110 shown in the figure.

[0121] refer to Figure 3The first electrode plate 111 may include a first electrode active material layer 111b configured to cover at least one surface of a first electrode current collector made of a plate-shaped metal foil, and may include a first electrode uncoated portion 111a uncoated by the first electrode active material layer 111b. The first electrode uncoated portion 111a may be used as a region in the electrode assembly 110 for current collection and electrical connection.

[0122] The second electrode plate 112 may include a second electrode active material layer 112b configured to cover at least one surface of a second electrode current collector made of a plate-shaped metal foil, and may include a second electrode uncoated portion 112a uncoated by the second electrode active material layer 112b. The second electrode uncoated portion 112a may perform the same function as the first electrode uncoated portion 111a, and may maximize the structural stability and electrical efficiency of the electrode assembly 110.

[0123] In some embodiments, the first electrode plate 111 and the second electrode plate 112 of the electrode assembly 110 may be configured such that the uncoated portions 111a and 112a of the first electrode do not overlap. In some embodiments, the first electrode active material layer 111b, the uncoated portion 111a, the second electrode active material layer 112b, and the uncoated portion 112a can be cut simultaneously. The first electrode active material layer 111b and the second electrode active material layer 112b can be cut simultaneously in the same process, and the first uncoated portion 111a and the second uncoated portion 112a can be cut simultaneously in the same process. This design can help simplify the process and improve productivity at the same time.

[0124] The uncoated portion 111a of the first electrode may extend in a first direction (x-axis) which is a longitudinal direction (e.g., the longitudinal direction of the current collector 110S), and may be positioned on one side in a second direction (y-axis) which is a transverse direction (e.g., the transverse direction of the current collector 110S). The uncoated portion 112a of the second electrode may extend in the first direction and may be positioned on the other side in the second direction. In some embodiments, the current collector 110S may be configured such that the uncoated portion 111a of the first electrode is exposed on one side in the second direction, and the uncoated portion 112a of the second electrode is exposed on the other side in the second direction. In some embodiments, the first direction (x-axis) may refer to a vertical direction, and the second direction (y-axis) may refer to a horizontal direction. The first direction may include a positive (+) direction and a negative (-) direction of the x-axis, respectively, representing one side and the other side. The second direction may include a positive (+) direction and a negative (-) direction of the y-axis, respectively, representing one side and the other side.

[0125] The uncoated portion 111a of the first electrode can extend in a first direction (x-axis) as the longitudinal direction, and can be positioned on one side in a second direction (y-axis) as the transverse direction. The uncoated portion 112a of the second electrode can extend in the same longitudinal direction (x-axis), and can be positioned on the opposite side in the transverse direction (y-axis). This arrangement can minimize interference in the electrode assembly and expose each uncoated portion for easy electrical connection.

[0126] In some embodiments, the current collector 110S can be cut into a pattern including a main region and protruding regions, the main region corresponding to the first electrode active material layer 111b, and the protruding regions protruding from the main region to each of the two sides in a second direction (y-axis).

[0127] In some embodiments, the current collector 110S can be cut into a pattern in which independent segments are arranged sequentially in a first direction (x-axis) as the longitudinal direction, each segment including: a main region corresponding to the first electrode active material layer 111b; and a protruding region, each protruding from the main region to one side and the other side in a second direction (y-axis).

[0128] The predetermined pattern for punching the current collector 110S can be a shape comprising a generally rectangular main region and protruding regions that bulge partially from one side and the other side of the main region. The predetermined pattern can be arranged sequentially in the longitudinal direction, allowing multiple current collectors to be punched at once. This pattern enables efficient punching and assembly of the current collector 110S.

[0129] In some embodiments, the area of ​​the first electrode active material layer 111b may be smaller than the area of ​​the second electrode active material layer 112b. This can optimize the electrical performance of the electrode assembly 110, reduce interference between individual electrode plates, and improve stacking stability.

[0130] In some embodiments, the area of ​​the diaphragm 113 may be larger than the area of ​​each of the first electrode active material layer 111b and the second electrode active material layer 112b. Increasing the area of ​​the diaphragm 113 can prevent electrical short circuits and enhance the durability of the electrode assembly 110.

[0131] In some embodiments, the current collector 110S can be configured such that the second electrode plate 112, the diaphragm 113, the first electrode plate 111, and the diaphragm 113 are stacked sequentially from the bottom. In some embodiments, the current collector 110S can be configured such that the diaphragm 113, the second electrode plate 112, the diaphragm 113, and the first electrode plate 111 are stacked sequentially from the bottom. The stacking structure can be flexibly adjusted. Variations in the stacking structure can be selectively adjusted according to process requirements and design goals.

[0132] In some embodiments, multiple current collectors 110S can be stacked, for example, at least two current collectors 110S. For example, instead of punching each current collector, multiple current collectors (e.g., at least two current collectors) can be stacked and then cut in a predetermined pattern at once. For example, not only can each current collector be punched individually, but multiple current collectors (e.g., at least two current collectors) can be stacked and then cut in a predetermined pattern at once. This can significantly increase the speed of the process and maximize productivity. For example, if multiple current collectors are punched in a stacked state at once, errors that may occur in each step can be reduced, and the quality of the electrode assembly can always be maintained. In one embodiment, the stacked multiple current collectors can be cut into another predetermined pattern.

[0133] Figure 4 This is an exploded perspective view of the current collector 210S, which includes an electrode assembly comprising a double-coated electrode plate.

[0134] refer to Figure 4 The first electrode plate 211 can be configured such that the uncoated portion 211a of the first electrode extends in the first direction (x-axis) at the center of the first electrode plate 211 in the second direction (y-axis).

[0135] The second electrode plate may include a first column of electrode plates 2121 and a second column of electrode plates 2122. The first column of electrode plates 2121 is configured such that the uncoated portion 2121a of the second electrode extends in a first direction (x-axis) and is located on one side in a second direction (y-axis), and the second column of electrode plates 2122 is configured such that the uncoated portion 2122a of the second electrode extends in the first direction (x-axis) and is located on the other side in the second direction (y-axis). In one embodiment, the first column of electrode plates 2121 may include the uncoated portion 2121a of the second electrode and a second electrode active material layer 2121b, and the second column of electrode plates 2122 may include the uncoated portion 2122a of the second electrode and a second electrode active material layer 2122b.

[0136] The current collector 210S can be configured such that the uncoated portions 2121a and 2122a of the second electrode are exposed on one side and the other side in the second direction (y-axis), respectively, and the uncoated portion 211a of the first electrode is formed (or exposed) along its centerline.

[0137] In some embodiments, the current collector 210S can be cut into a pattern that includes: a main region corresponding to the first electrode active material layer 211b; and a protruding region protruding from the main region in a direction toward each of the uncoated portion 211a of the first electrode and the uncoated portion 2121a of the second electrode located on the side of the second direction (y-axis).

[0138] In some embodiments, the current collector 210S can be cut into a pattern that includes: a main region corresponding to the first electrode active material layer 211b; and a protruding region protruding from the main region in a direction toward each of the uncoated portion 211a of the first electrode and the uncoated portion 2122a of the second electrode located on the other side in the second direction (y-axis).

[0139] In some embodiments, the current collector 210S can be cut into a pattern in which individual segments are arranged sequentially in a second direction (y-axis) relative to the uncoated portion 211a of the first electrode. Each segment includes: a main region corresponding to the active material layer 211b of the first electrode; and a protruding region protruding from the main region to each of one side and the other side in the second direction (y-axis). The pattern of the individual segments arranged sequentially in the second direction (y-axis) can be configured such that the protruding regions located at the uncoated portion 211a of the first electrode interlock with each other. This can reduce the area that is punched out and discarded.

[0140] Figure 5 This is an exploded perspective view of the current collector 310S, which includes an electrode assembly with a patterned coated electrode plate.

[0141] refer to Figure 5 The uncoated portion 311a of the first electrode can extend in a first direction (x-axis) as the longitudinal direction and can be positioned on one side in a second direction (y-axis) as the transverse direction. In some embodiments, the first electrode plate 311 can have uncoated portions 311a of the first electrode extending from one side in the second direction (y-axis) and spaced at regular intervals. In one embodiment, the current collector 310S can be configured such that the diaphragm 313, the second electrode plate 312, the diaphragm 313 and the first electrode plate 311 are stacked sequentially from the bottom. In one embodiment, the first electrode plate 311 may include the uncoated portion 311a of the first electrode corresponding to the first electrode tab 314 and the first electrode active material layer 311b, and the second electrode plate 312 may include the uncoated portion 312a of the second electrode corresponding to the second electrode tab 315 and the second electrode active material layer 312b.

[0142] In some embodiments, at least a portion of the uncoated portion 311a of the first electrode extending in the second direction (y-axis) of the current collector 310S may be cut off. In some embodiments, the uncoated portion 311a of the first electrode may be located not only at the upper and lower parts of the cut single current collector 310S, but also at the left and right sides of the cut single current collector 310S.

[0143] Thus, a patterned coating (intermittent coating) can be applied to the first electrode plate 311 to adjust misalignment winding. For example, by adjusting the spacing between uncoated portions through patterned coating (intermittent coating), it is possible to increase the possibility of assembling in the desired form during the punching process, or to achieve structural optimization that reduces material waste.

[0144] Figure 6 yes Figure 2 The diagram shows a plan view of the electrode assembly 110.

[0145] refer to Figure 6 The electrode assembly 110 may include: a first electrode plate 111 having a first electrode uncoated portion 111a, a portion of which is punched out, the first electrode uncoated portion 111a extending and protruding to one side in a second direction (y-axis); and a second electrode plate 112 having a second electrode uncoated portion 112a, a portion of which is punched out, the second electrode uncoated portion 112a extending and protruding to the other side in the second direction (y-axis). Although each of the first electrode plate 111 and the second electrode plate 112 of the electrode assembly 110 is shown as a single piece in the figures, a plurality of first electrode plates 111 and a plurality of second electrode plates 112 may be stacked with a plurality of diaphragms 113 between them.

[0146] The corners on both sides of each of the uncoated portions 111a and 112a of the first and second electrodes may be punched. The uncoated portions 111a and 112a may be respectively a first electrode tab 114 and a second electrode tab 115. The first electrode tab 114 and the second electrode tab 115 may be located on one side and the other side in the second direction (y-axis), respectively. The first electrode tab 114 and the second electrode tab 115 may have the same or different widths in the first direction (x-axis) and the same or different protrusion lengths in the second direction (y-axis).

[0147] Figure 7 yes Figure 4 The diagram shows a plan view of the electrode assembly 210.

[0148] refer to Figure 7The electrode assembly 210 may include a first electrode plate 211 having a first electrode uncoated portion 211a, a portion of which is punched out, and the first electrode uncoated portion 211a extending and protruding to one side in a second direction (y-axis); and a second electrode plate 212 having a second electrode uncoated portion 212a, a portion of which is punched out, and the second electrode uncoated portion 212a extending and protruding to the other side in the second direction (y-axis). Although each of the first electrode plate 211 and the second electrode plate 212 of the electrode assembly 210 is shown as a single piece in the figures, multiple first electrode plates 211 and multiple second electrode plates 212 may be stacked with multiple diaphragms 213 between them.

[0149] The uncoated portion 211a of the first electrode and the uncoated portion 212a of the second electrode may protrude asymmetrically (e.g., asymmetrically outward). The uncoated portion 211a and the uncoated portion 212a of the first electrode may be a first electrode tab 214 and a second electrode tab 215, respectively. The first electrode tab 214 and the second electrode tab 215 may be located on one side and the other side in a second direction (y-axis), respectively. Based on... Figure 7 The first electrode tab 214 can protrude from the left side in the second direction (y-axis), and the second electrode tab 215 can protrude from the right side in the second direction (y-axis). The first electrode tab 214 and the second electrode tab 215 can have the same or different widths in the first direction (x-axis) and the same or different protrusion lengths in the second direction (y-axis).

[0150] This disclosure provides a process that simultaneously improves the speed and accuracy of stacking and punching processes in the manufacture of electrode assemblies, reduces material waste, and provides flexibility for various structural designs. To this end, by optimizing the structure and arrangement of current collectors, patterning of stacking and punching processes, and material design, this disclosure overcomes the limitations of conventional processes.

[0151] This disclosure maximizes process efficiency not only by cutting a single current collector, but also by stacking two or more current collectors and punching them in one go. This method significantly reduces the time required to individually stack and cut each layer in existing processes, while producing electrode assemblies of consistent quality by cutting multiple current collectors with the same pattern.

[0152] This disclosure allows for current collectors with a specific pattern, including a main region and protruding regions, thereby reducing material waste during the punching process and ensuring the structural stability of the assembly. The protruding regions can be used to form electrical connections for the electrode assembly, and the size and position of the protruding regions can be flexibly adjusted according to the design requirements of the assembly.

[0153] In some embodiments, the stacking order can be changed by adjusting the stacking direction of the current collectors, enabling adaptation to various manufacturing environments and design requirements. Furthermore, by designing the location of uncoated portions and the spacing between them through patterned coating, this disclosure improves accuracy and reduces material waste in the punching process.

[0154] Thus, this disclosure provides a flexible process that can improve process speed and quality, reduce material waste, and meet various design requirements in the manufacturing of electrode components. In this way, manufacturing costs can be reduced and high-quality electrode components can be manufactured.

[0155] In some embodiments, the electrode assembly 110 can be applied to Figure 8 and Figure 9 The prism-shaped secondary battery 100 is shown in the figure.

[0156] Figure 8 This is a perspective view illustrating a secondary battery 100, and Figure 9 It is along Figure 8 The cross-sectional view taken from line II-II in the diagram.

[0157] refer to Figure 8 and Figure 9 The secondary battery 100 may include: at least one electrode assembly 110-1 wound with a separator 113-1 acting as an insulator between a negative electrode 111-1 and a positive electrode 112-1; a housing 2 in which the electrode assembly 110-1 is received (or housed); and a cover assembly 3 coupled to an opening in the housing 2.

[0158] The secondary battery 100 is described as a prismatic lithium-ion secondary battery. However, this disclosure is not limited thereto, and suitable aspects, features, and principles described herein can be applied to a variety of other types of batteries (such as lithium polymer batteries and / or cylindrical batteries).

[0159] Each of the negative electrode 111-1 and the positive electrode 112-1 may include a current collector made of a thin metal foil, the current collector having a coated portion coated with an active material and an uncoated portion 1-1a, 1-2a without an active material.

[0160] The negative electrode 111-1 and the positive electrode 112-1 are wound together after a diaphragm 113-1, which serves as an insulator, is placed between them. However, this disclosure is not limited thereto, and the electrode assembly 110-1 may have negative electrodes 111-1 and positive electrodes 112-1, each made of a plurality of sheets, stacked alternately, with the diaphragm placed between the negative electrodes 111-1 and the positive electrodes 112-1.

[0161] The housing 2 can form the overall appearance of the secondary battery 100 and may include a conductive metal, such as aluminum, aluminum alloy, or nickel-plated steel. The housing 2 can provide space to accommodate the electrode assembly 110-1.

[0162] The cover assembly 3 may include a cover plate 3-1 covering the opening of the housing 2, and the housing 2 and the cover plate 3-1 are made of conductive material. Negative electrode terminals 2-1 and positive electrode terminals 2-2, which are electrically connected to negative electrode 111-1 and positive electrode 112-1 respectively, may be mounted to pass through (or extend through) the cover plate 3-1 and protrude outward through the cover plate 3-1.

[0163] The outer peripheral surfaces (e.g., circumferential surfaces) of the upper posts of the negative electrode terminal 2-1 and the positive electrode terminal 2-2 protruding outward from the cover plate 3-1 can be threaded and can be fixed to the cover plate 3-1 by means of nuts.

[0164] This disclosure is not limited thereto, and the negative electrode terminal 2-1 and the positive electrode terminal 2-2 may have a riveted structure and may be riveted or welded to the cover plate 3-1.

[0165] The cover plate 3-1 can be made of a thin plate and can be connected to the opening of the housing 2, and the sealing plug 3-3 can be installed therein. The electrolyte injection port 3-2 can be located in the cover plate 3-1 (e.g., formed in the cover plate 3-1), and the venting portion 3-4 with the notch 3-4a can be installed.

[0166] The negative electrode terminal 2-1 and the positive electrode terminal 2-2 can be electrically connected to a current collector including a first current collector 4 and a second current collector 5 (hereinafter referred to as the positive electrode current collector and the negative electrode current collector) which are respectively (e.g., by welding) bonded or connected to the uncoated portion 1-1a of the negative electrode and the uncoated portion 1-2a of the positive electrode.

[0167] For example, negative electrode terminal 2-1 and positive electrode terminal 2-2 can be connected to negative electrode current collector 4 and positive electrode current collector 5 respectively by welding. However, this disclosure is not limited thereto, and in one or more embodiments, negative electrode terminal 2-1 and positive electrode terminal 2-2 can be integrally formed with negative electrode current collector 4 and positive electrode current collector 5 respectively.

[0168] An insulating member may be installed between the electrode assembly 110-1 and the cover plate 3-1. The insulating member may include a first lower insulating member 6 and a second lower insulating member 7, and each of the first lower insulating member 6 and the second lower insulating member 7 may also have a portion located between the electrode assembly 110-1 and the cover plate 3-1.

[0169] One end of the separating member can face one side of the electrode assembly 110-1 and can be installed between the insulating member and the negative electrode terminal 2-1 or the positive electrode terminal 2-2.

[0170] In some embodiments, the separating member may include a first separating member 8 and a second separating member 9.

[0171] In some embodiments, the first end of the first separating member 8 and the first end of the second separating member 9, which are mounted on one side facing the electrode assembly 110-1, can be respectively installed between the first lower insulating member 6 and the negative electrode terminal 2-1 and between the second lower insulating member 7 and the positive electrode terminal 2-2.

[0172] The negative electrode terminal 2-1, which can be soldered to the negative electrode current collector 4, can be connected to the first end of the first lower insulating member 6 and the first separating member 8. The positive electrode terminal 2-2, which can be soldered to the positive electrode current collector 5, can be connected to the first end of the second lower insulating member 7 and the second separating member 9.

[0173] The battery pack includes at least one battery module and a housing with a receiving space, wherein the at least one battery module is housed in the receiving space.

[0174] A battery module may include multiple battery cells and a module housing. The battery cells may be stacked (or arranged or configured in a stacked manner) and housed within the module housing. Each battery cell may have a positive electrode terminal and a negative electrode terminal, and may be cylindrical, prismatic, or pouch-shaped depending on its shape. As used herein, a battery cell may also be referred to as a secondary battery, a battery, or a cell.

[0175] In a battery pack, a single stacked unit can form a module that replaces a stack of battery modules. The stacked unit can be housed in the housing space of the pack casing, or in a housing space separated by frames, partitions, etc.

[0176] Battery cells may generate significant amounts of heat during charging / discharging. This heat can accumulate within the cells, accelerating their degradation. The battery pack may further include cooling components to remove / dissipate the generated heat, thereby inhibiting cell degradation. These cooling components may be located at the bottom of the housing where the battery cells are situated, but are not limited to this, and may be located at the top or side, depending on the battery pack.

[0177] A battery cell can be configured such that vents generated inside the battery cell under abnormal operating conditions (also known as thermal runaway or thermal events) are vented to the outside of the battery cell. A battery pack or battery module may include vents for venting these vents to prevent or reduce damage to the battery pack or module from the vents.

[0178] A battery pack may include batteries and a battery management system (BMS) for managing the batteries. The battery management system may include detection devices, balancing devices, and control devices. A battery module may include multiple individual cells connected in series and / or in parallel. Battery modules may be connected in series and / or in parallel.

[0179] The detection device can detect the state of the battery (e.g., voltage, current, temperature, etc.) to output state information indicating the battery's state. The detection device can detect the voltage of each individual cell constituting the battery or the voltage of each battery module. The detection device can detect the current flowing through each individual cell constituting the battery module or battery pack. The detection device can also detect the temperature of the individual cells and / or the module and / or the ambient temperature at at least one point within the battery.

[0180] The balancing device can perform balancing operations on the battery module and / or the individual cells constituting the battery module. The control device can receive state information (e.g., voltage, current, temperature, etc.) of the battery module from the detection device. The control device can monitor and calculate the state of the battery module (e.g., voltage, current, temperature, state of charge (SOC), lifespan (state of health (SOH)), etc.) based on the state information received from the detection device. In addition, based on the monitored state information, the control device can perform control functions (e.g., temperature control, balancing control, charge / discharge control, etc.) and protection functions (e.g., over-discharge, overcharge, overcurrent protection, short circuit, fire suppression, etc.). Furthermore, the control device can perform wired or wireless communication functions with external devices of the battery pack (e.g., higher-level controllers or vehicles, chargers, power conversion systems, etc.).

[0181] The control device can control the battery's charging / discharging operations and protection operations. Therefore, the control device may include a charging / discharging control unit, an equalization control unit, and / or a protection unit.

[0182] A battery management system is a system that monitors battery status and performs diagnostic and control, communication and protection functions. It can calculate charge / discharge status, calculate battery life or state of health (SOH), cut off battery power as needed (e.g., relay control), control thermal management (e.g., cooling, heating, etc.), perform high-voltage interlocking functions, and / or detect and / or calculate insulation and short-circuit conditions.

[0183] Relays can be mechanical contactors that are switched on and off by the magnetic force of a coil, or semiconductor switches (such as metal-oxide-semiconductor field-effect transistors (MOSFETs)).

[0184] The relay control has the function of cutting off the power supply from the battery if a problem occurs in the vehicle and battery system (or cutting off the power supply from the battery when a problem occurs in the vehicle and battery system), and may include one or more relays and a pre-charge relay at the positive and negative terminals respectively.

[0185] In precharge control, there is a risk of inrush current in the high-voltage capacitor on the inverter input side when a battery load is connected. Therefore, to prevent inrush current when starting the vehicle, the precharge relay can be operated before the main relay, and a precharge resistor can be connected.

[0186] High-voltage interlocking is a circuit that uses small signals to detect whether all high-voltage components of the entire vehicle system are connected, and can have the function of forcibly disconnecting the relay if an open circuit occurs in even one location of the entire circuit (or forcibly disconnecting the relay when an open circuit occurs in even one location of the entire circuit).

[0187] Figure 10 This is a perspective view illustrating battery module 20a.

[0188] refer to Figure 10 The battery module 20a includes terminal portions 14 and 15, a plurality of battery cells 100A arranged in one direction, a connecting tab 22 connecting one of the battery cells 100A to an adjacent battery cell 100b, and a protection circuit module 23 having one end connected to the connecting tab 22. The protection circuit module 23 may include a battery management system (BMS). The connecting tab 22 may include a body portion that contacts the terminal portions 14 and 15 between adjacent battery cells 100a and 100b, and an extension portion extending from the body portion and connecting to the protection circuit module 23. The connecting tab 22 may be, for example, a busbar.

[0189] Each battery cell 100A may include a battery casing, an electrode assembly received (or housed) within the battery casing, and an electrolyte. The electrode assembly and electrolyte undergo an electrochemical reaction to store and release (e.g., generate) energy. Terminals 14 and 15 electrically connected to the connecting tab 22, and an exhaust portion 17 serving as a venting channel for gases generated inside the battery casing, may be provided on one side (e.g., the upper side) of the battery cell 100A. Terminals 14 and 15 of the battery cell 100A may be positive electrode terminals 14 and negative electrode terminals 15 with different polarities, and the terminals 14 and 15 of adjacent battery cells 100a and 100b may be electrically connected in series or parallel to each other via the connecting tab 22, as will be described in more detail below. Although series connection has been described as an example, the connection structure is not limited thereto, and various connection structures may be employed as needed. The number and arrangement of battery cells are not limited to this. Figure 10 The structure shown can be modified according to needs or requirements.

[0190] Multiple battery cells 100A can be arranged in one direction (e.g., stacked in one direction) such that the wide surfaces of battery cells 100a and 100b face each other, and the multiple battery cells 100A can be secured by housings 26-1, 26-2, 26-3, and 26-4. Housings 26-1, 26-2, 26-3, and 26-4 can include a pair of end plates 26-1 and 26-2 facing the wide surfaces of battery cells 100A, and a side plate 26-3 and a bottom plate 26-4 connecting the pair of end plates 26-1 and 26-2 to each other. The side plate 26-3 can support the side surfaces of battery cells 100A, and the bottom plate 26-4 can support the bottom surfaces of battery cells 100A. The pair of end plates 26-1 and 26-2, the side plate 26-3, and the bottom plate 26-4 can be connected by bolts 26-5 and / or any other suitable fastening members and methods known to those skilled in the art.

[0191] The protection circuit module 23 may have electronic components and protection circuitry mounted thereon and may be electrically connected to the connecting tabs 22. The protection circuit module 23 includes a first protection circuit module 23a and a second protection circuit module 23b extending at different locations along the direction in which the plurality of battery cells 100A are arranged. The first protection circuit module 23a and the second protection circuit module 23b may be spaced apart from each other at a suitable interval (e.g., a predetermined interval) and arranged parallel to each other to be electrically connected to adjacent connecting tabs 22, respectively. For example, the first protection circuit module 23a extends along the direction in which the plurality of battery cells 100A are arranged on one side of the upper portion of the plurality of battery cells 100A, and the second protection circuit module 23b extends along the direction in which the plurality of battery cells 100A are arranged on the other side of the upper portion of the plurality of battery cells 100A. The second protection circuit module 23b may be spaced apart from the first protection circuit module 23a at a suitable interval (e.g., a predetermined interval), with the vent 17 located between them, but may be arranged parallel to the first protection circuit module 23a. Thus, the two protection circuit modules are arranged side-by-side and spaced apart from each other along the direction in which the multiple battery cells 100A are arranged, thereby reducing or minimizing the area of ​​the printed circuit board (PCB) constituting the protection circuit module. By separating the protection circuit modules into two protection circuit modules, unnecessary PCB area can be reduced or minimized. The first protection circuit module 23a and the second protection circuit module 23b can be connected to each other via a conductive connecting member 25-1. One side of the conductive connecting member 25-1 is connected to the first protection circuit module 23a, and the other side is connected to the second protection circuit module 23b, so that the two protection circuit modules 23a and 23b can be electrically connected to each other.

[0192] The connection can be performed by any of the following methods: brazing, resistance welding, laser welding, projection welding, and / or any other suitable connection method known to those skilled in the art.

[0193] The connecting member 25-1 can be, for example, an electrical wire. The connecting member 25-1 may include a material that is elastic or flexible. Via the connecting member 25-1, it is possible to check and manage whether the voltage, temperature, and / or current of multiple battery cells 100A are normal. For example, information (such as voltage, current, and / or temperature) received by the first protection circuit module from the connecting tab adjacent to the first protection circuit module, and information (such as voltage, current, and / or temperature) received by the second protection circuit module from the connecting tab adjacent to the second protection circuit module, can be integrated and managed by the protection circuit modules through the connecting member 25-1.

[0194] When the battery cell 100A expands, the elasticity or flexibility of the connecting member 25-1 can absorb the impact, thereby preventing damage to the first protection circuit module 23a and the second protection circuit module 23b.

[0195] The geometry and structure of the connecting member 25-1 are not limited to Figure 10 The shapes and structures shown in the figure.

[0196] Because the protection circuit module 23 is provided as a first protection circuit module 23a and a second protection circuit module 23b, the area of ​​the printed circuit board (PCB) constituting the protection circuit module can be reduced or minimized, and the space inside the battery module can be ensured. This improves work efficiency by simplifying the fastening work for connecting the connecting tab 22 and the protection circuit module 23, as well as the maintenance work if an abnormality is detected in the battery module (or when an abnormality is detected in the battery module).

[0197] Although the secondary battery 100A can be implemented as a single cell, it can also be used to manufacture battery packs containing multiple cells, or to manufacture larger battery packs by increasing the size of the individual cells.

[0198] Figure 11 and Figure 12 An illustrative perspective view of a battery pack 30 is shown. The battery pack 30 may include a plurality of battery modules 20b and a housing 31 for accommodating the plurality of battery modules 20b. For example, the housing 31 may include a first housing 31-1 and a second housing 31-2 connected in opposite directions relative to the plurality of battery modules 20b. The plurality of battery modules 20b may be electrically connected to each other using busbars 25, and the plurality of battery modules 20b may be electrically connected to each other in series / parallel or a hybrid series-parallel manner, thereby obtaining a desired (e.g., required) electrical output.

[0199] Figure 13 and Figure 14 Examples include perspective and side views of the vehicle body 40 and vehicle components. Figure 13 In this configuration, the battery pack 30 may include a battery pack cover 30-1 (which is part of the vehicle floor 41) and a frame 30-2 located below the vehicle floor 41. In some embodiments, the battery pack cover 30-1 may correspond to a first housing 31-1, and the frame 30-2 may correspond to a second housing 31-2. The frame 30-2 and the battery pack cover 30-1 may be integrated into the vehicle floor 42. The vehicle floor 41 separates the interior and exterior of the vehicle, and the frame 30-2 may be located on the exterior of the vehicle.

[0200] refer to Figure 14 The vehicle 50 can be formed by incorporating additional components, such as a hood 51 at the front of the vehicle and bumpers 52 at the front and rear of the vehicle, respectively, into the body 40. The vehicle 50 may include a battery pack 30, which includes a battery pack cover 30-1 and a battery pack frame 30-2, and the battery pack 30 may be coupled to the body 40.

[0201] As will be apparent from the embodiments of this disclosure, a method for manufacturing an electrode assembly for a secondary battery and an electrode assembly manufactured using the method can be provided, which can simultaneously improve process speed and accuracy by employing sub-cell stacking and batch punching in a stacking process, minimizing material waste and flexibly handling various assembly structures.

[0202] Although the present disclosure has been described above with reference to embodiments thereof, the present disclosure is not limited thereto. Those skilled in the art will be able to make various modifications and variations within the spirit of the present disclosure.

Claims

1. A method for manufacturing an electrode assembly for a secondary battery, the method comprising: A current collector is prepared, wherein a first diaphragm is inserted between a first electrode plate and a second electrode plate, wherein a second diaphragm is provided on a surface of the first electrode plate or a surface of the second electrode plate, and wherein the first electrode plate, the first diaphragm, the second electrode plate and the second diaphragm are stacked. The current collector is cut into a predetermined pattern; as well as The stacked and cut current collectors, The first electrode plate includes a first electrode active material layer and a first electrode uncoated portion. The first electrode active material layer includes a first electrode active material and covers at least one surface of the first electrode current collector. The first electrode uncoated portion is not coated with the first electrode active material. The second electrode plate includes a second electrode active material layer and a second electrode uncoated portion. The second electrode active material layer includes a second electrode active material and covers at least one surface of the second electrode current collector. The second electrode uncoated portion is not coated with the second electrode active material. The uncoated portions of the first electrode and the uncoated portions of the second electrode do not overlap. and During the cutting process, the first electrode active material layer, the uncoated portion of the first electrode, the second electrode active material layer, and the uncoated portion of the second electrode are cut simultaneously.

2. The method of claim 1, wherein the uncoated portion of the first electrode extends in the longitudinal direction of the current collector and is located on one side in the transverse direction of the current collector, and wherein the uncoated portion of the second electrode extends in the longitudinal direction and is located on the other side in the transverse direction.

3. The method of claim 2, wherein the uncoated portion of the first electrode is exposed on one side, and the uncoated portion of the second electrode is exposed on the other side.

4. The method of claim 2, wherein the predetermined pattern comprises: The main region corresponds to the first electrode active material layer; And protruding regions, protruding from the main region to each of the other side.

5. The method of claim 2, wherein the predetermined pattern comprises independent segments arranged sequentially in the longitudinal direction, each independent segment comprising: The main region corresponds to the first electrode active material layer; And protruding regions, protruding from the main region to each of the other side.

6. The method of claim 1, wherein the cutting is performed using a mold or a laser.

7. The method according to claim 1, wherein the area of ​​the first electrode active material layer is smaller than the area of ​​the second electrode active material layer.

8. The method according to claim 1, wherein the area of ​​each of the first membrane and the second membrane is greater than the area of ​​each of the first electrode active material layer and the second electrode active material layer.

9. The method of claim 1, wherein in the preparation, at least a portion of the current collector is fixed using a fixing member, and wherein in the stacking, the fixing member is removed.

10. The method of claim 2, wherein the first electrode uncoated portion of the first electrode plate has a plurality of first electrode uncoated portions extending from the side and spaced apart at regular intervals, and wherein, during the cutting, at least a portion of each of the plurality of first electrode uncoated portions extends in the lateral direction.

11. The method of claim 2, wherein the uncoated portion of the first electrode extends in the longitudinal direction at the center of the first electrode plate in the transverse direction, and the second electrode plate comprises: The first column of electrode plates has an uncoated portion of a second electrode extending in the longitudinal direction and located on one side; And a second column of electrode plates, having a second electrode uncoated portion extending in the longitudinal direction and located on the other side, wherein the second electrode uncoated portion of the second electrode plate includes the second electrode uncoated portion of the first column of electrode plates and the second electrode uncoated portion of the second column of electrode plates.

12. The method of claim 11, wherein the uncoated portion of the second electrode of the second electrode plate is exposed on each of the one side and the other side, and the uncoated portion of the first electrode is formed to be exposed along the centerline of the current collector.

13. The method of claim 11, wherein the predetermined pattern comprises: The main region corresponds to the first electrode active material layer; And a protruding region that protrudes from the main region in a direction toward each of the uncoated portion of the first electrode and the uncoated portion of the second electrode of the first column of electrode plates.

14. The method of claim 11, wherein the predetermined pattern comprises: The main region corresponds to the first electrode active material layer; And a protruding region that protrudes from the main region in a direction toward each of the uncoated portions of the first electrode and the uncoated portions of the second electrode of the second column of electrode plates.

15. The method of claim 11, wherein the predetermined pattern comprises independent segments arranged sequentially in the lateral direction relative to the uncoated portion of the first electrode, each independent segment comprising: The main region corresponds to the first electrode active material layer; And protruding regions, protruding from the main region to each of the other side.

16. The method of claim 15, wherein the plurality of protruding regions located at the uncoated portion of the first electrode are engaged with each other.

17. The method of claim 1, further comprising: The stacked multiple current collectors are cut into another predetermined pattern.

18. The method of claim 1, wherein the second electrode plate, the first diaphragm, the first electrode plate and the second diaphragm are stacked sequentially, or wherein the second diaphragm, the second electrode plate, the first diaphragm and the first electrode plate are stacked sequentially.

19. An electrode assembly for a secondary battery, the electrode assembly comprising: Multiple first electrode plates, each having an uncoated portion of the first electrode, a portion of the uncoated portion of the first electrode being punched out, and the uncoated portion of the first electrode extending and protruding to one side; as well as Multiple second electrode plates, each having an uncoated portion of the second electrode, a portion of which is punched out, and the uncoated portion of the second electrode extends and protrudes to a side opposite to the stated side. The diaphragm is located between each of the plurality of first electrode plates and each of the plurality of second electrode plates.

20. The electrode assembly of claim 19, wherein the corners on both sides of each of the uncoated portions of the first electrode and the second electrode are punched, or wherein each of the uncoated portions of the first electrode and the second electrode protrudes asymmetrically outward.

Images