Battery Tab Sealing Grid Structure for Gas Leak Resistance
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Solution Overview
Problem
Secondary batteries face issues with insufficient adhesive strength and pressure resistance in their sealing portions, leading to potential damage during repeated charging and discharging, which can result in gas leakage and reduced reliability.
Innovation Solution
The implementation of a tab sealing portion with repeating patterns, such as grid patterns, and a resin filling portion between these patterns, along with a tab sealing film, enhances the mechanical reliability and prevents gas leakage by dispersing stress and acting as a gas barrier, while an apparatus with sealing blocks featuring grid pressing patterns forms these sealing portions during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional sealing portion is used without repeating patterns, then the manufacturing process is simple, but the adhesive strength and pressure resistance are insufficient
Solution Approach 1:
The sealing portion is divided into multiple grid patterns that are repeatedly arranged. Each grid pattern acts as an independent sealing unit, collectively providing enhanced adhesive strength and pressure resistance while maintaining manufacturability through standardized repeating structures.
Solution Approach 2:
The sealing portion combines multiple materials including a sealing layer, adhesive layer, and optionally a reinforcement layer with repeating grid patterns. This composite structure integrates the advantages of different materials to achieve both high strength and reasonable manufacturing complexity.
2Stress or pressure
If a conventional sealing portion is used without repeating patterns, then the manufacturing process is simple, but the pressure resistance is insufficient
Solution Approach 1:
The sealing portion is segmented into multiple grid patterns that distribute mechanical stress across numerous small units. This segmentation prevents stress concentration at any single point, significantly improving pressure resistance while the repeating nature of the patterns keeps manufacturing complexity manageable.
Solution Approach 2:
The grid patterns are specifically designed with optimized local geometries at the sealing interface to enhance pressure resistance. The repeating patterns allow this locally optimized structure to be applied uniformly across the entire sealing portion, balancing performance improvement with manufacturing feasibility.
3Reliability
If the sealing portion is disassembled due to insufficient adhesive strength, then gas leakage occurs, but using a simpler sealing structure would reduce manufacturing complexity
Solution Approach 1:
The sealing portion uses multiple grid patterns that create numerous small sealing zones. This segmentation ensures that if one zone experiences stress, the surrounding zones maintain sealing integrity, preventing gas leakage while the repeating structure keeps manufacturing complexity reasonable.
Solution Approach 2:
The adhesive layer is positioned between the sealing layer and electrode tab to provide beforehand cushioning. This adhesive cushioning prevents direct stress transmission that could cause disassembly, ensuring sealing reliability while maintaining a relatively simple multi-layer structure.
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 solution significantly improves the stability and reliability of secondary batteries by enhancing pressure resistance and preventing gas leakage, thereby extending the lifespan and ensuring the integrity of the battery during expansion.
Implementation Method 1
The repeating pattern may disperse a stress generated during expansion of the exterior material, thereby preventing damages of the exterior material and a release sealing
Implementation Method 2
A resin filling portion formed between the grid patterns... acting as a gas barrier, while an apparatus with sealing blocks featuring grid pressing patterns forms these sealing portions during manufacturing
Implementation Method 3
sealant layers included in the exterior material facing each other may be fused by heating and pressing to form the sealing portion
Data Source
AI summary
A secondary battery, an apparatus for processing the secondary battery and a method of manufacturing the secondary battery are provided. The secondary battery includes an electrode assembly including an electrode tab, and an exterior material accommodating the electrode assembly and including a sealing portion formed around the electrode assembly. The sealing portion includes a tab sealing portion formed at an area where the electrode tab is drawn out, and the tap sealing portion includes repeating patterns.