Secondary Battery Cell Assembly With Shorter Tabs for Higher Energy Density
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Solution Overview
Problem
Existing secondary battery manufacturing methods do not adequately enhance energy density, leaving room for improvement in this critical aspect.
Innovation Solution
A method involving the preparation of a case main body with openings, an electrode assembly with tabs, and sealing plates, where the electrode assembly is inserted and sealed in a specific manner to optimize energy density, including the use of spacers to facilitate insertion and reduce tab length, thereby increasing the volume occupied by the electrodes within the case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the electrode assembly is inserted into the case main body with the electrode tabs extending outside, then the electrical connection can be made, but the volume occupied by electrodes within the case is reduced and energy density is lowered
Solution Approach 1:
The sealing plates are attached to the electrode tabs before inserting the electrode assembly into the case main body. This preliminary action allows the electrode tabs to be shorter since they don't need to extend outside the case for connection - the sealing plates with connection terminals are already in position to receive the tabs, enabling electrical connection while maximizing electrode volume within the case
Solution Approach 2:
The sealing plates are positioned within the case main body structure, with connection terminals that receive the electrode tabs. This nesting arrangement allows the electrode assembly to be inserted with tabs extending only partially outside, while the sealing plates provide the connection interface, effectively reducing the required tab length and increasing the volume available for active electrode material
2Stability of the object's composition
If the electrode assembly is pressed into the case main body during insertion, then the assembly is stabilized, but the electrode tabs may be damaged
Solution Approach 1:
The sealing plates are attached to the electrode tabs before insertion, creating a reinforced structure. This preliminary attachment provides mechanical support to the tabs during the pressing operation, distributing the applied force and preventing tab damage while ensuring stable insertion of the electrode assembly into the case main body
Solution Approach 2:
The sealing plates serve as a cushioning element attached beforehand to the electrode tabs. During insertion, these sealing plates absorb and distribute the pressing forces, protecting the vulnerable electrode tabs from damage while maintaining insertion stability. The sealing plates act as a buffer that prevents direct transmission of excessive force to the tabs
Data Source
AI summary
A method of manufacturing a secondary battery includes: inserting an electrode assembly into a case main body from the second end portion side of the electrode assembly through a first opening after electrically connecting a first electrode terminal and a first electrode tab to each other; electrically connecting a second electrode terminal and a second electrode tab to each other after inserting the electrode assembly into the case main body, a second electrode terminal being provided on a second sealing plate; sealing the first opening with a first sealing plate after inserting the electrode assembly into the case main body; and sealing a second opening with the second sealing plate after electrically connecting the second electrode terminal and the second electrode tab to each other.