Secondary Battery Electrode Assembly Overlap for Higher Energy Density
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Solution Overview
Problem
Existing secondary battery manufacturing methods struggle to achieve improved energy density and stable production processes.
Innovation Solution
A method of manufacturing a secondary battery that involves producing electrode assemblies with separate electrode tabs, joining these tabs to current collectors, and overlapping the electrode assemblies to facilitate electrical connections and enhance energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode tabs are joined to current collectors after producing electrode assemblies, then the manufacturing process becomes more flexible and reliable, but the manufacturing complexity increases
Solution Approach 1:
The electrode assemblies are produced first with electrode tabs extending from them, and then the tabs are joined to current collectors in subsequent steps. This preliminary arrangement of components allows for more reliable connections while maintaining a structured manufacturing process.
Solution Approach 2:
The manufacturing process is divided into distinct sequential steps: producing electrode assemblies, joining tabs to current collectors, and overlapping assemblies. This segmentation allows each step to be optimized independently, improving reliability without overwhelming complexity.
2Ease of manufacture
If the first current collector and third current collector are constituted of separate components, then the manufacturing flexibility improves, but the device complexity increases
Solution Approach 1:
The current collector system is divided into separate components: a first current collector joined to the first electrode tab, and a third current collector joined to the third electrode tab. This segmentation provides manufacturing flexibility while the components are integrated through the overlapping arrangement of electrode assemblies.
Solution Approach 2:
The electrode assemblies themselves act as intermediaries that connect the separate current collectors. The first and third current collectors are not directly connected but are electrically connected through the electrode assemblies, simplifying the overall structure while maintaining flexibility.
3Quantity of substance
If electrode assemblies are overlapped after joining tabs to current collectors, then energy density improves, but the manufacturing precision requirements increase
Solution Approach 1:
The electrode assemblies are produced with predetermined configurations including extending tabs before the overlapping step. This preliminary preparation ensures that when assemblies are overlapped, the alignment and positioning can be achieved with appropriate precision, enabling higher energy density.
Solution Approach 2:
The manufacturing process allows for controlled changes in the positioning and orientation parameters of electrode assemblies during the overlapping step. By carefully controlling these parameters, high energy density is achieved while maintaining feasible manufacturing precision requirements.
Data Source
AI summary
A method of manufacturing a secondary battery includes: after producing a first electrode assembly and a second electrode assembly, electrically connecting a second electrode tab and a fourth electrode tab to a second current collector with the first electrode assembly being disposed on one side with respect to the second current collector and the second electrode assembly being disposed on the other side with respect to the second current collector; and after joining the second electrode tab and the fourth electrode tab, bending the second electrode tab and the fourth electrode tab such that the first electrode tab and the third electrode tab face each other so as to overlap the first electrode assembly and the second electrode assembly with each other.