Secondary Battery Tab Connection Segmentation
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Solution Overview
Problem
In secondary batteries, the need to connect multiple electrode assembly tabs to a common terminal simultaneously leads to material waste and increased risk of short circuits due to excessive tab length and potential misalignment.
Innovation Solution
The design involves bending and connecting tabs from adjacent electrode assemblies to each other and then to a central terminal, allowing for reduced tab length, minimizing material usage, and preventing insertion into the battery body, thus reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the length of tabs is increased to compensate for dislocations during assembly, then all tabs can be connected to electrode terminals simultaneously, but material waste increases and the risk of short circuits increases
Solution Approach 1:
The tab connection process is segmented into two stages: first, tabs of adjacent electrode assemblies are connected to each other; second, the connected tabs are gathered and connected to electrode terminals. This segmentation eliminates the need for all tabs to reach terminals simultaneously, allowing shorter tabs that do not penetrate into electrode assemblies.
Solution Approach 2:
The solution introduces a spatial dimension change by first connecting tabs in the lateral direction (between adjacent electrode assemblies) before gathering them vertically to the terminals. This dimensional transition allows tabs to be connected without requiring excessive length, reducing material waste and short circuit risks.
2Ease of manufacture
If the length of tabs is increased to compensate for dislocations during assembly, then all tabs can be connected to electrode terminals simultaneously, but the risk of short circuits increases due to tabs being inserted into electrode assembly
Solution Approach 1:
The tab connection process is segmented into two stages: first, tabs of adjacent electrode assemblies are connected to each other; second, the connected tabs are gathered and connected to electrode terminals. This segmentation eliminates the need for all tabs to reach terminals simultaneously, allowing shorter tabs that do not penetrate into electrode assemblies.
Solution Approach 2:
Tabs of adjacent electrode assemblies are connected to each other in advance before being gathered to the terminals. This preliminary connection action ensures proper alignment and positioning, eliminating the need for excessively long tabs that could penetrate into electrode assemblies and cause short circuits.
3Productivity
If tabs of multiple electrode assemblies are gathered together to connect to terminals at the same time, then connection is achieved, but tab length must be increased resulting in material waste
Solution Approach 1:
The tab connection process is segmented into two stages: first, tabs of adjacent electrode assemblies are connected to each other; second, the connected tabs are gathered and connected to electrode terminals. This segmentation eliminates the need for all tabs to reach terminals simultaneously, allowing shorter tabs that do not penetrate into electrode assemblies.
Solution Approach 2:
Tabs of multiple electrode assemblies are merged by connecting adjacent tabs together first, forming a unified structure. This merging allows the tabs to be gathered and connected to terminals as a group rather than individually, reducing the required length of each tab and minimizing material waste.
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 approach reduces tab length requirements, conserves materials, and lowers the risk of short circuits by eliminating the need for compensating for tab misalignments during assembly.
Implementation Method 1
the second tabs are bent toward a direction approaching the first tabs and connected to the first tabs
Implementation Method 2
Each of the first tabs includes a first connecting portion extending beyond the second end portion, and the first connecting portion is connected to the first electrode terminal
Data Source
AI summary
The present application provides a secondary battery, which includes a first electrode assembly, a second electrode assembly, a case, and a top cap assembly. The top cap assembly includes a top cap plate and a first electrode terminal, the top cap plate is connected to the case, and the first electrode terminal is arranged on the top cap plate. The first electrode assembly includes a first body and first tabs extending from the first body, and the first tabs are multiple and stacked. The second electrode assembly includes a second body and second tabs extending from the second body, and the second tabs are multiple and stacked. An end of each of the second tabs that is away from the second body is a second end portion. Each of the first tabs includes a first connecting portion extending beyond the second end portion.