Secondary Battery Current Collector Layout for Compact Tab Assembly
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Solution Overview
Problem
Existing secondary batteries for electric vehicles and hybrid electric vehicles face challenges in achieving high volumetric energy density and efficient assembly due to complex terminal connection configurations.
Innovation Solution
A secondary battery design featuring a rectangular outer body with a sealing plate, positive and negative electrode tab groups, and a dual current collector system where one of the tab groups is connected to the terminal via a first and second current collector, with the second current collector being welded to the first collector in a bent configuration, allowing for easier assembly and higher energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If current collecting tabs are welded to leads while bent relative to the winding axis, then the battery achieves compact structure, but the assembly process becomes complex
Solution Approach 1:
The current collector is divided into multiple sections: a first section connected to the electrode assembly, a second section that is bent, and a third section connected to the terminal. This segmentation allows each section to perform its specific function optimally while simplifying the overall assembly process by enabling pre-bending of the current collector before final assembly.
Solution Approach 2:
The current collector is pre-bent into the required configuration before being assembled with the electrode assembly and terminal. This preliminary action of bending the current collector separately allows for easier handling and assembly, avoiding the complexity of bending and welding operations during final assembly.
2Volume of moving object
If current collectors are configured in complex bent shapes, then space utilization improves, but manufacturing precision requirements increase
Solution Approach 1:
The current collector is segmented into distinct sections with clear functional boundaries. The first section maintains a relatively simple configuration for connection to the electrode assembly, the second section contains the necessary bends for space optimization, and the third section provides a stable mounting surface for the terminal. This segmentation reduces the cumulative precision requirements compared to a single complex bent shape.
Solution Approach 2:
The bent configuration of the current collector is established as a preliminary component before final assembly. This allows the bends to be formed with controlled precision in a dedicated manufacturing step, rather than requiring high precision during the final welding and assembly operations where multiple tolerances would accumulate.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The configuration enables the production of secondary batteries with higher volumetric energy density and simplified manufacturing, enhancing reliability and performance.
Implementation Method 1
the second current collector is welded to the second section
Data Source
AI summary
Provided is a secondary battery in which an electrode body having a positive electrode tab group on one end thereof is accommodated in a battery case, wherein: a first positive electrode current collector comprises a first region disposed between a sealing plate and the electrode body, and a second region disposed between the electrode body and a first side wall of a rectangular exterior body constituting the battery case; the positive electrode tab group is connected in a folded state to a second positive electrode current collector; and the second positive electrode current collector is welded to the second region.