Secondary Battery Electrode Assembly Without Welded Current Paths

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Solution Overview

Problem

Existing secondary battery electrode substrates made of metal are heavy, and the welding process for forming conductive layers can lead to quality deterioration.

Innovation Solution

An electrode assembly design featuring a first electrode portion with electrodes, separators, and electrode tabs, and a second electrode portion with metal plates and coupling tabs that surround and are coupled to the electrode tabs, forming a current path without welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metal substrate is used for electrode assembly, then electrical conductivity is improved, but weight increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidweight of electrode assembly

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The electrode assembly is divided into multiple individual electrodes (positive and negative electrodes) that are stacked alternately with separators. Each electrode is a thin, lightweight structure rather than a single heavy metal substrate, reducing overall weight while maintaining conductivity through the distributed electrode structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrodes are constructed as composite structures with metal layers formed on insulating film layers. This composite design provides electrical conductivity through the metal layers while the insulating film layers reduce weight and prevent short circuits, achieving both conductivity and weight reduction

Inventive Principle:

Principle #40Composite materials

2Reliability

If welding process is used to form conductive layers, then electrical connection is improved, but quality deterioration occurs

Engineering Contradiction:

Improveelectrical connectionVSAvoidquality of electrode assembly

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The welding process (thermal/mechanical system) is replaced with a direct physical contact and adhesion-based connection system. The metal layers on the insulating films are directly contacted and connected through the electrode structure design, eliminating the welding process that causes quality deterioration while maintaining electrical connection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The insulating film layers serve as intermediaries between the metal layers. Instead of directly welding metal substrates, the metal layers are formed on the insulating films which mediate the connection, preventing direct metal-to-metal contact and the associated welding quality issues while ensuring electrical conductivity

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This design reduces weight and improves quality by eliminating the need for welding, enhancing the structural integrity and conductivity of the electrode assembly.

Implementation Method 1

a metal layer formed on first and second surfaces of the insulating film layer

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20260074184A1Electrode assembly and secondary battery including same

Publication Date: 2026.03.12 SAMSUNG SDI CO LTD

AI summary

The present disclosure relates to an electrode assembly including a first electrode portion including a plurality of electrodes, a separator, and an electrode tab on each of the plurality of electrodes. The electrode assembly may further include a second electrode portion on at least one surface of the first electrode portion and electrically connected to the electrode tab.