Battery Electrode Assembly With Recessed Internal Lead-Tab Welding
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Solution Overview
Problem
Existing battery designs face challenges in efficiently coupling electrode plates within the battery assembly, leading to reduced battery size and capacity due to external welding portions, and a complex manufacturing process.
Innovation Solution
The battery design includes an electrode assembly with negative and positive electrode plates alternately stacked with separators, where lead tabs with welding portions are positioned inside the assembly, simplifying the manufacturing process and increasing capacity by internalizing the welding areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lead tabs are positioned outside the electrode assembly, then welding is easier to perform, but battery size increases and capacity decreases
Solution Approach 1:
The patent applies nesting by positioning the lead tabs inside the electrode assembly, where the first lead tab is located in the first recess of the negative electrode current collector and the second lead tab is located in the second recess of the positive electrode current collector. This internal positioning allows the welding portions to be nested within the battery structure rather than extending externally, thereby reducing overall battery size while maintaining welding functionality.
Solution Approach 2:
The patent utilizes the recesses in the current collectors to accommodate lead tabs in a different spatial arrangement. By creating recesses in the current collector structure, the lead tabs can be positioned in a different dimensional space within the battery, allowing welding to occur internally without increasing the external footprint of the battery.
2Ease of manufacture
If lead tabs are positioned outside the electrode assembly, then welding access is improved, but battery capacity is reduced
Solution Approach 1:
The lead tabs are nested within the electrode assembly structure, with the first lead tab positioned in the first recess of the negative electrode current collector and the second lead tab positioned in the second recess of the positive electrode current collector. This nesting eliminates the need for external welding portions, maximizing the volume available for active materials and thereby increasing battery capacity.
Solution Approach 2:
The patent merges the lead tab positioning with the current collector structure by creating recesses in the current collectors that accommodate the lead tabs. This integration eliminates separate external welding portions and combines multiple functions (current collection and lead tab accommodation) into a single integrated structure, improving capacity.
3Ease of manufacture
If external welding portions are used, then manufacturing is simpler, but battery size and complexity increase
Solution Approach 1:
The patent merges the lead tab accommodation function with the current collector structure by forming recesses in the current collectors. This integration eliminates the need for separate external welding portions and reduces structural complexity while maintaining manufacturing simplicity through a unified design approach.
Solution Approach 2:
The lead tabs are nested within the current collector recesses, creating a compact integrated structure. This nesting reduces the number of separate components and simplifies the overall battery structure by eliminating external welding portions, thereby reducing complexity while maintaining ease of manufacture.
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 enhances battery capacity and reduces size by internalizing welding portions within the electrode assembly, improving manufacturing efficiency and performance.
Implementation Method 1
the first tab portion of the negative electrode is welded to the first lead tab so as to form a first welding portion located in the first recess of the negative electrode current collector, and wherein the second tab portion of the positive electrode is welded to the second lead tab so as to form a second welding portion located in the second recess of the positive electrode current collector
Data Source
AI summary
A battery may include: a negative electrodes including a negative electrode including a first tab portion, and a negative electrode current collector including a first recess; positive electrodes arranged alternately with the negative electrodes, and including a positive electrode including a second tab portion, and a positive electrode current collector including a second recess; a separator between two adjacent electrodes among the negative electrodes and the positive electrodes; a first lead tab in the first recess; and a second lead tab in the second recess, wherein the first tab portion is welded to the first lead tab so as to form a first welding portion located in the first recess, and the second tab portion is welded to the second lead tab so as to form a second welding portion located in the second recess.