Secondary Battery Tab Layout for Breakage-Resistant Assembly
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Solution Overview
Problem
Conventional secondary battery assembly methods risk damaging the electrode assembly due to uneven force distribution, particularly when one electrode tab is pulled and fixed to a current collector, leading to potential breakage.
Innovation Solution
The secondary battery design includes a housing with distinct openings for negative and positive electrode tabs, where one tab is longer than the other to allow for adjustable sagging, reducing the force applied to the assembly and incorporating insulating members to prevent electrical conduction between tabs and the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode tabs are fixed to current collectors on both sides of the case body, then electrical connections are established, but the electrode assembly may be damaged due to uneven force distribution
Solution Approach 1:
The patent applies asymmetry by making one electrode tab longer than the other. The first electrode tab extends beyond the first current collector, while the second electrode tab does not extend beyond the second current collector. This asymmetric configuration allows the longer tab to absorb assembly forces and misalignments, preventing damage to the electrode assembly while maintaining reliable electrical connections on both sides.
Solution Approach 2:
The patent implements beforehand cushioning by designing the first electrode tab to be longer and extend beyond the first current collector. This extra length acts as a cushion that absorbs assembly forces and misalignments before they can be transmitted to the electrode assembly, thereby protecting it from damage during the assembly process.
2Reliability
If electrode tabs are rigidly fixed to current collectors, then stable electrical connections are achieved, but the electrode assembly is vulnerable to damage from assembly forces
Solution Approach 1:
The asymmetric tab configuration allows the longer first electrode tab to serve as a force-absorbing element that protects the electrode assembly from assembly-induced damage while maintaining stable electrical connections through the current collectors.
Solution Approach 2:
The longer first electrode tab acts as an intermediary element between the assembly forces and the electrode assembly. It absorbs and dissipates assembly forces before they can reach the electrode assembly, while still maintaining the electrical connection pathway through the current collector.
3Shape
If both electrode tabs are the same length, then symmetric assembly is achieved, but force distribution becomes uneven causing potential breakage
Solution Approach 1:
The patent deliberately breaks symmetry by making the first electrode tab longer than the second electrode tab. This asymmetric design creates a more favorable force distribution during assembly, with the longer tab absorbing excess forces that would otherwise cause breakage in a symmetric configuration.
Data Source
AI summary
A secondary battery includes: an electrode assembly including a first end portion where one or more negative electrode tabs are formed, and a second end portion where one or more positive electrode tabs are formed; a housing containing the electrode assembly; and a negative electrode terminal and a positive electrode terminal provided on the housing, the housing includes a main body, a first sealing body, and a second sealing body, the negative electrode terminal is provided on the first sealing body, the positive electrode terminal is provided on the second sealing body, the one or more negative electrode tabs are electrically connected to the negative electrode terminal, the one or more positive electrode tabs are electrically connected to the positive electrode terminal, and one of the one or more negative electrode tabs and the one or more positive electrode tabs is larger in length than the other.