Bent Electrode Tab Layout for Reliable Current Collector Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional secondary battery manufacturing process is complicated and costly due to the need for welding two electrode tabs to a current collector, leading to potential welding omissions and increased material and production costs.
Innovation Solution
The process is simplified by bending each electrode tab towards a central area of the electrode assembly, allowing for easier welding of a current collector, reducing the complexity and cost of the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two electrode tabs are formed on each electrode plate to prevent welding omissions, then welding reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The electrode tabs are pre-bent towards the central area of the electrode assembly before the welding process. This preliminary positioning action ensures that all tabs are automatically aligned with the current collector, preventing welding omissions while simplifying the welding process to a single operation rather than requiring multiple tabs per electrode plate
Solution Approach 2:
Multiple electrode tabs from different electrode plates are bent to converge at the central area, merging their positions to a common welding zone. This allows the current collector to weld all tabs simultaneously in one operation, reducing process complexity while maintaining reliability
2Reliability
If two electrode tabs are formed on each electrode plate, then welding reliability is improved, but manufacturing cost increases
Solution Approach 1:
The electrode tabs are pre-bent towards the central area of the electrode assembly before the welding process. This preliminary positioning action ensures that all tabs are automatically aligned with the current collector, preventing welding omissions while simplifying the welding process to a single operation rather than requiring multiple tabs per electrode plate
Solution Approach 2:
The solution extracts the essential function of preventing welding omissions from the quantity of tabs (two per electrode plate) and relocates it to the positioning method (bending towards central area). This allows using only one tab per electrode plate while achieving the same reliability through proper positioning
3Productivity
If electrode tabs are bent towards central area, then welding efficiency is improved, but tab shape complexity increases
Solution Approach 1:
The electrode tabs are bent into a curved shape towards the central area of the electrode assembly. This curvature allows the tabs to reach the central welding zone from their original positions, improving welding efficiency by consolidating all welds to one location while accommodating the geometric constraints of the electrode plate arrangement
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 approach enhances the welding efficiency, reduces the likelihood of welding omissions, and lowers production costs while maintaining the integrity of the electrode connections.
Implementation Method 1
The welding process is referred to as laser plate welding (LPW)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A secondary battery includes: an electrode assembly (40) including a plurality of electrode plates, each including an electrode tab (44a, 44b) bent toward a central area of the electrode assembly (40); a current collector (41, 42) welded to the bent electrode tabs (44a, 44b); and a terminal (62, 63) electrically connected to the current collector (41, 42).