Secondary Battery Tab-to-Terminal Joining for Higher Energy Density
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Solution Overview
Problem
Secondary batteries face challenges in increasing volumetric energy density due to space requirements for current collecting tabs and leads, which complicates the manufacturing process and increases costs.
Innovation Solution
The direct ultrasonic joining of current collecting tabs to electrode terminals within the battery container eliminates the need for external leads, reducing the space between the lid and electrode body and enhancing energy density while simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leads and current collecting tabs are provided between the output terminal and the electrode body, then electrical connection is achieved, but the volumetric energy density decreases due to space occupation
Solution Approach 1:
The patent merges the current collecting tab and the lead into a single integrated component. The current collecting tab is directly formed from the current collector foil and extends outward to serve as the electrical connection element, eliminating the need for separate leads. This integration reduces the space required for electrical connections while maintaining reliable electrical connectivity between the electrode body and the external circuit.
2Reliability
If separate leads and current collecting tabs are used for electrical connection, then reliable electrical connection is achieved, but the manufacturing process becomes complex and costs increase
Solution Approach 1:
The patent combines multiple components (current collector foil, current collecting tab, and lead) into a single integrated structure where the current collecting tab is directly formed from the current collector foil and extends outward. This eliminates the need for separate joining operations between tabs and leads, simplifying the manufacturing process while ensuring reliable electrical connection.
Solution Approach 2:
The patent extracts and eliminates the unnecessary lead component from the system by directly using the current collecting tab as the electrical connection element. This removal of redundant components simplifies the manufacturing process and reduces assembly steps while maintaining the essential electrical connection function.
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 configuration increases the volumetric energy density and reduces manufacturing costs by eliminating the need for leads and simplifying assembly, allowing for either increased battery capacity or reduced size.
Implementation Method 1
a secondary battery comprises an outer container, an electrode terminal attached to the outer container and including a first junction surface exposed to an outside of the outer container and a second junction surface exposed to an inside of the outer container and opposing the first junction surface, and an electrode body housed in the outer container, including an electrode group and a current collecting tab group containing a plurality of current collecting tabs extending from the electrode group and directly joined to the second junction surface of the electrode terminal
Data Source
AI summary
According to one embodiment, a secondary battery includes an outer container, an electrode terminal attached to the outer container and including a first junction surface exposed to an outside of the outer container and a second junction surface exposed to an inside of the outer container and opposing the first junction surface, and an electrode body housed in the outer container, including an electrode group and a current collecting tab group containing a plurality of current collecting tabs extending from the electrode group and directly joined to the second junction surface of the electrode terminal.