Battery Cell Tab-Lead Orientation to Shrink Bonding Terrace Space

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Solution Overview

Problem

Existing battery cells have inefficiencies in space utilization due to the disposition of electrode tabs, which limits energy density.

Innovation Solution

The battery cell design includes an electrode assembly with an electrode tab and lead bonded in a specific orientation, covered by a protective member, and configured to minimize the space required for bonding, using a protective member to cover the bonding portion and reduce the terrace size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If electrode tabs are disposed in a conventional orientation, then the bonding structure is simple, but the space required for electrode tab disposition increases, reducing energy density

Engineering Contradiction:

Improveenergy densityVSAvoidspace for electrode tab disposition

Core Design Contradiction:

Quantity of substanceVSArea of stationary object

Solution Approach 1:

The electrode lead is configured to extend in the thickness direction of the electrode assembly rather than parallel to the stacking direction. This dimensional change allows the bonding portion to face the electrode assembly surface, significantly reducing the lateral space required for electrode tab disposition and thereby increasing energy density.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Instead of extending the electrode lead parallel to the stacking direction (conventional approach), the invention inverts this arrangement by extending the lead in the thickness direction. This inversion repositions the bonding portion to face the electrode assembly, optimizing space utilization.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If the bonding portion is exposed without protection, then the structure is simple, but the bonding area is vulnerable to damage and short-circuiting

Engineering Contradiction:

Improveprotection of bonding areaVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A protective member made of insulating material is introduced as an intermediary element between the electrode components and the external environment. This protective member covers the bonding portion, preventing damage and short-circuiting while maintaining structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective member is formed as a thin insulating structure that conforms to the bonding portion geometry. This thin film approach provides effective protection without significantly increasing device complexity or volume.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentEP4290675B1Battery cell and method of manufacturing the same

Publication Date: 2025.10.22 SK ON CO LTD

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AI summary

A battery cell includes an electrode assembly, an electrode tab drawn out from one surface of the electrode assembly, and an electrode lead to which the electrode tab is coupled, wherein a bonding portion in which the electrode tab and the electrode lead are bonded to each other is disposed to face the electrode assembly, and wherein, in the bonding portion, an end of the electrode tab and an end of the electrode lead are disposed to be oriented in the same direction.