Secondary Battery Tab Layout for Capacity and Easier Assembly

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Solution Overview

Problem

Existing secondary batteries face challenges in achieving increased capacity and improved process characteristics, particularly in the design and formation of electrode tabs which affect the overall performance and efficiency.

Innovation Solution

The secondary battery design includes first and second electrode tabs formed in different shapes and orientations, with specific configurations such as stripe type, notched, overlapping, and lead tabs, connected to distinct current collector plates, enhancing the manufacturing process and capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If tabs are formed in different shapes and orientations, then processability and capacity are improved, but device complexity increases

Engineering Contradiction:

Improvetab formation processabilityVSAvoidtab configuration complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The electrode assembly is divided into multiple tabs (first tab and second tab) with different shapes and orientations, allowing each tab to be optimized for specific manufacturing processes while maintaining overall battery performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the electrode assembly have tabs with different shapes and orientations tailored to local requirements, enabling optimized current collection and manufacturing processability in different areas of the battery

Inventive Principle:

Principle #3Local quality

2Quantity of substance

If tabs are formed in different shapes and orientations, then capacity increases, but manufacturing complexity increases

Engineering Contradiction:

Improvebattery capacityVSAvoidtab configuration complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The battery capacity is enhanced by segmenting the current collection into multiple tabs with different shapes and orientations, allowing optimized active material distribution and current collection efficiency across different regions of the electrode assembly

Inventive Principle:

Principle #1Segmentation

3Reliability

If first tab is connected to case and second tab to cap plate, then electrical connection is improved, but structural complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnection structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrical connection structure merges the tab-forming process with the sealing structure, where the first tab connects to the case and the second tab connects to the cap plate, creating an integrated electrical and mechanical connection system that enhances reliability while maintaining manufacturing simplicity

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4636884A1Secondary battery

Publication Date: 2025.10.22 SAMSUNG SDI CO LTD

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AI summary

A secondary battery includes a case and an electrode assembly accommodated in a space inside of the case. The electrode assembly includes a first tab connected to a first electrode plate and a second tab connected to a second electrode plate. A cap plate seals the case. The first tab and the second tab are formed in different shapes.