Secondary Battery Electrode Tab Asymmetry for Terminal Plate Coupling
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Solution Overview
Problem
Secondary batteries used in portable electronic devices and hybrid electric vehicles face challenges in minimizing space and conforming to curved device designs, with existing designs not effectively enhancing the coupling force between electrode tabs and terminal plates, leading to inefficiencies in space utilization and safety.
Innovation Solution
The secondary battery design features an obliquely formed sectional surface of the electrode tab, which corresponds to the shape of the terminal plate, improving the coupling force and process margin by positioning the first long side near the center and the second long side near the outer edge, and using a terminal plate with curved long sides and a folded configuration to enhance welding area and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the electrode tab is designed with a conventional rectangular shape, then the manufacturing process is simple, but the coupling force between the electrode tab and terminal plate is insufficient
Solution Approach 1:
The electrode tab is designed with an asymmetric shape where one long side is formed at an angle different from the other long side relative to the sectional surface. This asymmetric configuration allows the electrode tab to conform to the terminal plate geometry, improving coupling force while maintaining manufacturing feasibility through standard cutting processes.
Solution Approach 2:
Different regions of the electrode tab are designed with different geometric properties - specifically, the two long sides have different angles relative to the sectional surface. This local variation in geometry optimizes the contact area and coupling force at specific locations without requiring complete redesign of the entire tab structure.
2Adaptability or versatility
If the battery is designed with a flat shape, then the manufacturing process is simple, but the battery cannot conform to curved surfaces of electronic devices
Solution Approach 1:
The terminal plate is designed with curved long sides instead of straight edges, creating a geometry that can conform to curved surfaces of electronic devices. This curvature allows the battery assembly to adapt to ergonomic device designs while maintaining a relatively simple overall structure.
3Reliability
If the electrode tab has a standard rectangular configuration, then the welding area is limited, but the assembly process is straightforward
Solution Approach 1:
The asymmetric configuration of the electrode tab with differently angled long sides increases the effective welding area by creating better contact geometry with the terminal plate. This enhanced contact area improves welding reliability without significantly complicating the assembly process, as the shape can still be produced through standard cutting operations.
Data Source
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AI summary
A secondary battery includes: an electrode assembly; an electrode tab electrically connected to the electrode assembly and protruding at an end of the electrode assembly; a case accommodating the electrode assembly; a cap plate coupled to the case; and a terminal plate between the cap plate and the electrode assembly and electrically connected to the electrode tab, and the electrode tab includes first and second long sides parallel to a lengthwise direction of the electrode tab, and a sectional surface connecting the first and second long sides, and an angle between the first long side and the sectional surface is greater than 90 degrees.