Rechargeable Battery Lead Tab Segmentation for Flatness
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Solution Overview
Problem
Existing rechargeable batteries face challenges in maintaining flatness and capacity due to the design of lead tabs, which can deform the electrode assembly and require redesigning tab gaps for different sizes, affecting the external appearance and performance.
Innovation Solution
The rechargeable battery design incorporates a lead tab structure with a thin inner tab and a thicker outer tab, where the inner tab is connected to the electrode assembly and drawn out, allowing for adjustable tab gaps and improved flatness and capacity by using aluminum and copper electrodes with insulating tape for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a conventional lead tab design is used, then the battery can be manufactured, but the electrode assembly deforms and flatness deteriorates
Solution Approach 1:
The lead tab is divided into two distinct parts: an inner tab with smaller dimensions that contacts the electrode assembly, and an outer tab with larger dimensions that provides structural support. This segmentation allows each part to fulfill its specific function - the inner tab minimizes deformation of the electrode assembly while the outer tab ensures overall structural stability and facilitates external connections.
Solution Approach 2:
Different regions of the lead tab structure are given different properties - the inner tab has smaller width and thickness to reduce local impact on the electrode assembly and maintain flatness, while the outer tab has larger dimensions to provide robust structural support and ease of handling. This local differentiation resolves the contradiction between maintaining shape and ensuring reliability.
2Adaptability or versatility
If the tab gap is fixed for a specific battery size, then manufacturing is simplified, but adaptability to different battery sizes is reduced
Solution Approach 1:
The lead tab structure incorporates adjustability in the tab gap between the inner and outer tabs, allowing the configuration to be dynamically adapted to different battery sizes and applications. This dynamic feature enables the same basic structure to serve multiple purposes while maintaining optimal performance across different scales.
Solution Approach 2:
The dual-tab structure serves multiple functions simultaneously: the inner tab provides electrical connection and maintains electrode flatness, the outer tab provides structural support and facilitates external connections, and the adjustable gap between them accommodates different battery configurations. This multi-functionality achieves adaptability without proportionally increasing complexity.
3Strength
If the inner tab has larger dimensions, then connection strength is improved, but the area coated with active material is reduced
Solution Approach 1:
The lead tab is segmented into inner and outer portions with distinct functions. The inner tab maintains compact dimensions to preserve maximum electrode surface area for active material coating, while the outer tab provides the necessary structural strength and connection capability. This segmentation resolves the contradiction by distributing the strength requirement across different parts of the structure.
Solution Approach 2:
The lead tab structure functions as a composite system where the inner tab (smaller dimensions) and outer tab (larger dimensions) work together to achieve both high connection strength and maximum active material area. The combination of these two elements provides properties that neither element could achieve alone.
Data Source
Figure 1
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Figure 3~4
AI summary
A rechargeable battery, including an electrode assembly including wound electrodes with a separator therebetween; a pouch housing the electrode assembly; and lead tabs connected to the electrodes and drawn out of the pouch, the lead tabs including an inner tab having a first thickness, connected to the electrode, and drawn out of the electrode assembly.