Pouch Battery Tab Segmentation for Lower Tab Thickness
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Solution Overview
Problem
Existing secondary battery designs face challenges in maximizing battery capacity due to the thickness and number of substrate tabs, which affect internal space utilization and energy efficiency during the welding and bending process.
Innovation Solution
The design incorporates a configuration where multiple substrate tabs on both negative and positive electrode plates are spaced apart and welded to a single strip terminal, reducing the thickness and number of stacked tabs, thereby minimizing the occupied space within the pouch and increasing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple substrate tabs are gathered at one side and welded to external tabs, then electrical connection is achieved, but the thickness and occupied space of the bent substrate tabs increase, reducing internal space utilization
Solution Approach 1:
The substrate tabs are divided into two groups: first substrate tabs extending from the first end of the electrode assembly and second substrate tabs extending from the second end. This segmentation allows each group to be welded to separate external tabs at opposite ends, distributing the electrical connection points and reducing the thickness and occupied space where tabs would otherwise be stacked and bent at a single location.
Solution Approach 2:
Instead of gathering all substrate tabs at one side (two-dimensional concentration), the invention distributes them along the length of the electrode assembly (utilizing the third dimension). The first substrate tabs are positioned at one end while the second substrate tabs are positioned at the opposite end, effectively using the longitudinal dimension to spread out the connections and minimize local tab accumulation.
2Reliability
If multiple substrate tabs are stacked and bent at one location, then electrical connection is established, but energy consumption and equipment size increase
Solution Approach 1:
The welding and bending operations are segmented into two separate locations at opposite ends of the electrode assembly. Instead of stacking and bending multiple tabs at a single location (which would require higher energy and larger equipment), the process distributes these operations across two locations, reducing the energy demand and equipment size requirements at each individual welding station.
3Reliability
If substrate tabs are gathered at one side, then electrical connection is achieved, but internal space utilization is reduced, decreasing battery capacity
Solution Approach 1:
By segmenting the substrate tabs into two groups positioned at opposite ends of the electrode assembly, the invention minimizes the space occupied by bent tabs within the pouch. This segmentation strategy frees up internal space that would otherwise be consumed by a large accumulation of bent tabs at a single location, thereby increasing the volume available for active materials and electrolyte, and ultimately enhancing battery capacity.
Solution Approach 2:
The invention utilizes the longitudinal dimension of the electrode assembly to distribute substrate tabs along its length rather than concentrating them laterally at one side. This dimensional redistribution reduces the lateral space required for tab accommodation, optimizing the internal pouch space for energy-storing components and improving overall battery capacity.
Data Source
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Figure 3A~3B
AI summary
A secondary battery includes an electrode assembly including a negative electrode plate including a plurality of first negative electrode substrate tabs and a plurality of second negative electrode substrate tabs, a positive electrode plate including a plurality of first positive electrode substrate tabs and a plurality of second positive electrode substrate tabs, and a separator between the negative electrode plate and the positive electrode plate; a pouch accommodating the electrode assembly; a first strip terminal electrically connected to the plurality of first negative electrode substrate tabs and the plurality of second negative electrode substrate tabs; and a second strip terminal electrically connected to the plurality of first positive electrode substrate tabs and the plurality of second positive electrode substrate tabs.