Secondary Battery Current Collector Structure for Stable Tab Welding
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Solution Overview
Problem
Existing lithium secondary batteries face challenges in achieving high energy density and capacity, necessitating improvements in their power efficiency and manufacturing processes.
Innovation Solution
The secondary battery design incorporates specific structural features such as tab members, sub-plates, and current collectors with enhanced welding lines and bending portions to improve electrical connectivity and stability, along with a manufacturing method that forms these components to enhance power efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional battery structures are used, then manufacturing simplicity is maintained, but power efficiency and energy density are insufficient
Solution Approach 1:
The current collector is divided into multiple segments (first current collector, second current collector, third current collector) with distinct functions. Each segment handles specific electrical connections and current collection tasks, reducing resistance and improving power efficiency while maintaining manageable structural complexity through modular design.
Solution Approach 2:
The patent introduces a three-dimensional current collector structure with extensions in multiple directions (first extension, second extension, third extension). This spatial arrangement optimizes current collection paths and reduces electrical resistance, significantly improving power efficiency without proportionally increasing manufacturing complexity.
2Reliability
If conventional tab connections are used, then manufacturing process is simple, but electrical connectivity and stability are insufficient
Solution Approach 1:
The patent merges the tab function with the current collector by making the tab an integrated part of the current collector structure. This unified design eliminates separate tab components and their associated connection points, improving electrical connectivity and stability while simplifying the manufacturing process through reduced assembly steps.
Solution Approach 2:
The current collector is designed with pre-formed extensions and integrated tab structures that are created during the current collector fabrication process itself. This preliminary formation of connection structures eliminates subsequent assembly operations, maintaining ease of manufacture while achieving superior electrical connectivity.
3Quantity of substance
If battery structure is optimized for energy density, then capacity increases, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs specific geometric parameters for the current collector extensions (lengths, widths, thicknesses) that are optimized to achieve high energy density. By carefully controlling these dimensional parameters within defined ranges, the design maximizes active material volume while maintaining adequate current collection, achieving high energy density without excessive manufacturing precision requirements.
Solution Approach 2:
The current collector serves multiple functions simultaneously: it collects current, provides structural support, enables electrical connections, and defines the battery's energy density through its geometric configuration. This multi-functionality reduces the need for additional specialized components, allowing energy density optimization without proportionally increasing manufacturing precision demands.
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
The enhanced structural design and manufacturing method lead to increased power efficiency and stability of lithium secondary batteries, addressing the demand for higher energy density and capacity.
Implementation Method 1
a first sub-welding line on the first sub-plate and the first tab member connecting the first sub-plate to the first tab member
Data Source
AI summary
A secondary battery includes: a case; an electrode assembly inside the case; a cap assembly sealing the case and including a first terminal and a second terminal; a first tab member extending from the electrode assembly in a first direction; a first sub-plate between the electrode assembly and the case and connected to the first tab member; and a first current collector connected to the first terminal and the first sub-plate.