Battery Tab Current Collector Structure for Defect-Free Bonding
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Solution Overview
Problem
Existing secondary batteries face issues with electrode bonding defects and inefficient power utilization, which can lead to reduced performance and increased installation space requirements.
Innovation Solution
The secondary battery design includes a first tab member with a first insertion hole, a first inner current collector, and a first outer current collector, where the tab member thickness decreases towards its end, and guide parts are alternately disposed to facilitate secure bonding and efficient power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrode bonding methods are used, then manufacturing process is simple, but bonding defects occur and power efficiency is reduced
Solution Approach 1:
The current collector is divided into inner and outer current collectors that are positioned at different locations relative to the tab member. The inner current collector is inserted into the insertion hole of the tab member while the outer current collector is disposed outside the tab member, creating a segmented structure that ensures reliable bonding without requiring complex bonding processes
Solution Approach 2:
The inner current collector acts as an intermediary element that is inserted into the insertion hole of the tab member, facilitating secure bonding between the tab member and the outer current collector. This intermediary structure prevents bonding defects by ensuring proper alignment and contact between components
2Power
If larger installation space is provided, then electrode assembly can be accommodated, but power efficiency is reduced
Solution Approach 1:
The current collector structure utilizes three-dimensional spatial arrangement by positioning the inner current collector inside the tab member's insertion hole and the outer current collector outside the tab member. This dimensional optimization allows efficient power transfer while minimizing the overall installation space of the battery
3Reliability
If tab member thickness is uniform, then manufacturing is simple, but bonding reliability is reduced
Solution Approach 1:
The tab member is designed with non-uniform thickness where the first portion (at the insertion hole region) has a different thickness than the second portion (extending from the electrode). This local quality variation ensures reliable bonding at the insertion hole while maintaining ease of manufacture for the majority of the tab member structure
Data Source
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AI summary
The present disclosure relates to a secondary battery, a secondary battery manufacturing method, and a battery pack, in which defects in bonding of an electrode can be prevented or substantially prevented and power efficiency is increased. To this end, the present disclosure provides a secondary battery including a case, an electrode assembly disposed inside the case and having a first electrode and a second electrode, a first tab member connected to the first electrode and having a first insertion hole, a cap plate coupled to the case and disposed to face the electrode assembly, a first inner current collector inserted into the first insertion hole, a first outer current collector disposed to face the first inner current collector with the first tab member interposed therebetween, and a first terminal connected to the first outer current collector and extending outward from the cap plate.