Secondary Battery Tab Welding with Tape-Stabilized Electrode Stacks
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Solution Overview
Problem
Existing methods for manufacturing secondary batteries often result in defects such as damage or disconnection of electrode tabs during the welding process, and are prone to welding defects like weak or excessive welding.
Innovation Solution
A method and apparatus for manufacturing secondary batteries that involves preparing a tape of required size and shape, gathering electrode tabs to form a stack, taping the stack with the tape, and welding the taped stack to an electrode lead using laser welding, thereby preventing damage and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating layer is formed on the surface of the electrode before winding to prevent dendrite formation, then battery reliability is improved, but manufacturing complexity increases due to additional coating steps
Solution Approach 1:
The patent applies preliminary action by forming the coating layer on the electrode surface before the winding process. This ensures the coating is in place before any potential dendrite formation can occur during battery operation, while integrating the coating step into the existing manufacturing flow to avoid excessive complexity
Solution Approach 2:
The coating layer serves multiple functions: it prevents dendrite formation, protects the electrode surface, and maintains electrolyte distribution. By making the coating multi-functional, the patent reduces the need for additional separate components or processes, thereby improving reliability without proportionally increasing manufacturing complexity
2Manufacturing precision
If slurry is coated uniformly on the current collector to ensure consistent electrode quality, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent implements continuous slurry coating rather than batch processing. The slurry is applied continuously as the current collector moves through the coating apparatus, ensuring uniform coating across the entire electrode surface while maintaining high production speed and minimizing downtime between coating operations
Solution Approach 2:
The patent replaces traditional mechanical brushing or rolling methods with a more efficient coating mechanism that achieves superior uniformity. This substitution enables faster coating application with consistent thickness control, improving manufacturing precision without the time penalty associated with slower mechanical methods
3Volume of moving object
If the electrode is wound tightly to reduce battery volume, then space utilization is improved, but internal stress increases leading to potential deformation
Solution Approach 1:
The patent applies local quality by varying the winding tension across different sections of the electrode. The coating layer's enhanced adhesion and flexibility allow for optimized local tension distribution, enabling tight winding in some areas while maintaining structural integrity in others, thus reducing overall battery volume without causing deformation
Solution Approach 2:
The patent uses the composite structure of the coating layer combined with the electrode material to achieve both compact winding and structural strength. The coating layer's specific mechanical properties complement the electrode, creating a composite structure that can withstand tight winding forces while maintaining integrity, thereby reducing battery volume without compromising strength
Data Source
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AI summary
The present invention relates to an apparatus and method for manufacturing a secondary battery and a secondary battery manufactured thereby, and more particularly, to an apparatus and method for manufacturing a secondary battery, in which defects such as damage or disconnection of an electrode tab does not occur while the electrode tab and an electrode lead of an electrode assembly are connected through welding, and welding defects such as weak welding or excessive welding occurs are prevented from occurring to realize excellent quality, and a secondary battery manufactured there