Secondary Battery Tab-Collector Structure for Defect-Free Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing secondary batteries face issues with electrode bonding defects and inefficient power utilization, which affect the installation space for electronic components.
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 a traditional electrode bonding structure is used, then the manufacturing process is simple, but bonding defects occur and power efficiency is reduced
Solution Approach 1:
The current collector is divided into multiple segments including a first current collector, a second current collector, and a third current collector. Each segment has specific functions: the first current collector bonds with the tab member, the second current collector provides structural support, and the third current collector enhances electrical connection. This segmentation allows each part to be optimized for its specific function, improving bonding reliability while maintaining manufacturing feasibility through modular assembly.
Solution Approach 2:
The patent introduces a multi-layered current collector structure that extends in multiple dimensions. The current collectors are arranged in a stacked configuration with different orientations and positions relative to the tab member. This dimensional approach creates a three-dimensional bonding network that enhances both mechanical strength and electrical conductivity, resolving the contradiction between bonding quality and structural complexity.
2Power
If the tab member thickness is uniform, then manufacturing is easier, but power efficiency is reduced
Solution Approach 1:
The tab member is designed with non-uniform thickness distribution, where different regions have different thicknesses optimized for their specific functions. The region near the electrode connection has greater thickness for mechanical strength, while the region near the current collector interface has optimized thickness for electrical conductivity and bonding surface area. This local quality variation improves power efficiency by ensuring each region performs optimally, while the overall shape can still be manufactured using standard processes with minimal additional complexity.
Data Source
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.