Battery Electrode Assembly with Projecting Tab Design

Solution Overview

Problem

Conventional battery architectures face challenges in forming connections between electrode assemblies and terminals, which often compromise electrical conductivity, shock resistance, real estate, seal strength, cell lifespan, and manufacturability, with terminal components within the cell housing affecting electrical behavior and occupying additional space.

Innovation Solution

The electrode assembly features a jelly roll configuration with projecting tabs formed from the electrode sheets, where a subsection of the sheets contacts each other at an axial end, and a conductive tab is coupled to these tabs to electrically connect the assembly to a battery terminal, eliminating the need for intermediate coupling components and allowing for efficient electrolyte injection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional terminal components are used to connect electrode assembly to battery terminal, then connection is established, but electrical conductivity deteriorates and additional space is occupied

Engineering Contradiction:

Improveelectrical conductivityVSAvoidspace occupation

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent extracts and eliminates the intermediate terminal components from the battery architecture. By directly integrating the electrode assembly tabs with the battery terminal through welding or mechanical attachment, the patent removes the need for separate terminal components, thereby improving electrical conductivity and reducing space occupation within the battery housing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the electrode assembly connection function with the battery terminal structure. The tab from the electrode assembly is directly coupled to the battery terminal, combining what were previously separate components (terminal components and electrode assembly) into an integrated connection structure, eliminating intermediate elements and improving overall electrical conductivity.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If conventional terminal components are used, then connection is established, but device complexity increases

Engineering Contradiction:

Improveconnection stabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates intermediate terminal components from the battery architecture. By directly integrating the electrode assembly tabs with the battery terminal through welding or mechanical attachment, the patent removes the need for separate terminal components, thereby improving electrical conductivity and reducing space occupation within the battery housing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the electrode assembly connection function with the battery terminal structure. The tab from the electrode assembly is directly coupled to the battery terminal, combining what were previously separate components (terminal components and electrode assembly) into an integrated connection structure, eliminating intermediate elements and improving overall electrical conductivity.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If intermediate coupling components are used, then connection is established, but manufacturability deteriorates

Engineering Contradiction:

Improveconnection stabilityVSAvoidmanufacturability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates intermediate terminal components from the battery architecture. By directly integrating the electrode assembly tabs with the battery terminal through welding or mechanical attachment, the patent removes the need for separate terminal components, thereby improving electrical conductivity and reducing space occupation within the battery housing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs preliminary action by forming the tabs as an integral part of the electrode assembly during the winding process. This pre-formed tab structure is then directly attached to the battery terminal, eliminating the need for complex intermediate assembly steps and improving manufacturability.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10651453B2Electrode assembly with projecting tab for battery and methods of forming same

Publication Date: 2020.05.12 CUSTOM ELECTRONICS

AI summary

Embodiments of the disclosure provide an electrode assembly including: a jelly roll electrode having a plurality of electrode sheets, the plurality of electrode sheets including an anode sheet, a cathode sheet, and a separator separating the anode sheet from the cathode sheet, an electrolyte disposed between the anode sheet and the cathode sheet of the jelly roll electrode, and a tab projecting from an axial end of the plurality of electrode sheets, the tab including a subsection of the plurality of electrode sheets contacting each other at an axial end of the jelly roll electrode; and a first conductive tab coupled to the tab of the electrode assembly, wherein the first conductive tab is configured to electrically couple the electrode assembly to a battery terminal.