Secondary Battery Electrode Tabs With Layered Multi-Tab Winding

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Solution Overview

Problem

Existing secondary batteries face challenges in forming multi-tabs while minimizing non-coating portions, which can reduce battery capacity and increase electric resistance.

Innovation Solution

A secondary battery design featuring an electrode with a coating portion coated with active material and a non-coating portion, where a notching tab part is formed by notching the electrode to extend from the coating portion in a width direction, perpendicular to the longitudinal direction, and overlapping to form two or more layers when wound.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a multi-tab structure is formed by increasing non-coating portions on the electrode, then the electrical connection is improved and resistance is reduced, but the battery capacity is lowered due to the increased non-coating portion

Engineering Contradiction:
Improveelectrical connectionVSAvoidbattery capacity
Core Design Contradiction:
ReliabilityVSQuantity of substance

Solution Approach 1:

The electrode tab is segmented into multiple tabs (first tab and second tab) that are separated by a slit extending from the end of the electrode. This segmentation allows multiple electrical connection points without requiring large non-coating portions, as each tab can be independently connected to the current collector while maintaining active material coverage on the remaining electrode surface.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The tabs are arranged in different spatial dimensions and orientations on the electrode surface. The first tab extends in a first direction while the second tab extends in a second direction different from the first direction, allowing efficient use of the electrode width and length to accommodate multiple tabs without significantly increasing the total non-coating area.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Reliability

If the number of electrode tabs is increased to reduce resistance, then the electrical connection is improved, but the mechanical strength of individual tabs is reduced

Engineering Contradiction:
Improveelectrical connectionVSAvoidmechanical strength of tab
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The electrode is divided into multiple tabs through slits that extend from the electrode end, creating separate tab regions. Each tab maintains sufficient width and structural integrity while providing multiple connection points. The segmentation is achieved by controlled cutting that preserves the mechanical strength of each individual tab while distributing the electrical connection load across multiple tabs.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The electrode structure has different local properties: the tab regions are designed with specific dimensions and orientations to optimize both mechanical strength and electrical connection, while the active material regions maintain high coating density for capacity. The slit positions and tab dimensions are locally optimized to balance mechanical and electrical requirements.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS12334493B2Secondary battery and method for manufacturing the same
Publication Date: 2025.06.17 LG ENERGY SOLUTION LTD
  • US12334493B2 patent drawing
  • US12334493B2 patent drawing
  • US12334493B2 patent drawing

AI summary

The present invention relates to a secondary battery in which an electrode tab is improved in mechanical strength and a method for manufacturing the same. Also, the secondary battery according to the present invention includes: an electrode provided with a coating portion coated with an active material on an electrode collector and a non-coating portion on which the active material is not applied to the electrode collector, the non-coating portion being adjacent to the coating portion in a width direction perpendicular to a longitudinal direction of the electrode collector, the non-coating portion having a plurality of notching tabs formed therein such that each of the plurality of notching tabs extends away from the coating portion in a width direction. When the electrode assembly is in the wound state, the plurality of notching tabs are circumferentially distributed about a central axis of the electrode assembly.