Secondary Battery Electrode Assembly Layout for Reliable High Energy Density
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Solution Overview
Problem
Conventional secondary batteries face challenges in achieving high energy density and reliability.
Innovation Solution
The manufacturing method involves producing first and second electrode assemblies with specific tab configurations, overlapping and connecting them with stacked current collectors, and inserting them into a case with sealed terminals, enhancing the electrical connections and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrode assembly configurations are used, then manufacturing simplicity is maintained, but energy density and reliability cannot be sufficiently increased
Solution Approach 1:
The battery is divided into multiple electrode assemblies (first and second electrode assemblies) with different tab configurations. Each assembly is segmented to have specific tabs (first electrode tab, second electrode tab, third electrode tab, fourth electrode tab) positioned at different end portions, allowing independent connection to current collectors and enabling complex electrical connections without increasing overall manufacturing complexity
Solution Approach 2:
The invention utilizes spatial arrangement by disposing electrode assemblies and current collectors in three-dimensional space. Current collectors are positioned to extend in different directions (first current collector in first direction, second current collector in second direction), creating a multi-dimensional connection architecture that increases energy density while maintaining manufacturing feasibility
2Reliability
If simple current collector connections are used, then manufacturing ease is maintained, but electrical connection reliability and energy density are insufficient
Solution Approach 1:
Electrode tabs are joined to current collectors before the final assembly step. The first electrode tab is joined to the first current collector, and the second and fourth electrode tabs are joined to the second current collector in advance, allowing these connections to be made when access is easier and then integrated into the final battery structure
Solution Approach 2:
The current collector system is segmented into multiple independent current collectors (first current collector, second current collector, third current collector) that can be manufactured and connected separately. Each current collector handles specific electrode tabs, dividing the complex connection task into manageable segments that improve both reliability and manufacturing ease
3Quantity of substance
If electrode assemblies are arranged in conventional configurations, then structural simplicity is maintained, but space utilization and energy density are limited
Solution Approach 1:
The invention transitions from planar arrangement to three-dimensional spatial configuration. Current collectors extend in different directions (first direction, second direction, third direction) and electrode assemblies are positioned to overlap or adjacently arrange in space. This multi-dimensional arrangement maximizes space utilization within the battery case, increasing energy density without requiring proportionally increased structural complexity
Solution Approach 2:
The battery structure employs nested arrangement where current collectors and electrode assemblies are positioned within each other's spatial envelope. The first current collector, second current collector, and third current collector are arranged to overlap or adjacently nest in three-dimensional space, allowing maximum packing density of active materials while maintaining electrical connection pathways
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In a secondary battery, a first electrode assembly (201) and a second electrode assembly (202) are overlapped with each other. A first electrode tab (250) and a third electrode tab (280) each connected to a first electrode (240) and respectively included in the first electrode assembly (201) and the second electrode assembly (202) are joined to a first current collector (431). The first current collector (431) is constituted of a first stack in which a plurality of metal plates (4300) are stacked. A second electrode (210) of each of the first electrode assembly (201) and the second electrode assembly (202) has a polarity different from that of the first electrode (240). A second electrode tab (220) and a fourth electrode tab (270) each connected to the second electrode (210) are joined to a second current collector (410).