Multilayer Cell Tab Lead Arrangement for Thickness Reduction
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Solution Overview
Problem
The existing layered structure of cell units increases thickness due to overlapping tab portions, leading to decreased productivity and complexity in layering processes, especially when tab leads are shifted to reduce thickness.
Innovation Solution
A cell structure unit comprising two sheet-shaped cells with tab leads connecting their electrodes, where the tab leads are arranged to extend outside the cells, allowing for parallel connection while maintaining a thin profile and preventing short-circuits with insulating members, and the thickness of the tab leads is minimized to match or be less than the cells' thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If tab portions are overlapped in a layered structure of cell sheets, then cell capacity is increased, but cell thickness is increased
Solution Approach 1:
The patent transitions from a conventional in-plane tab arrangement to a face-to-face three-dimensional configuration. By arranging tabs of adjacent cells to face each other and using tab leads that extend between facing tabs, the connection structure moves from a two-dimensional planar layout to a three-dimensional spatial arrangement, enabling thinner overall cell structure while maintaining parallel connection capability
Solution Approach 2:
The patent divides the tab connection function into separate components: tabs remain on cell surfaces while tab leads are distinct connecting elements that extend between cells. This segmentation allows the leads to be positioned in the space between cells rather than requiring overlapping tab portions, thereby reducing cell thickness while preserving electrical connection functionality
2Length of stationary object
If tab leads are shifted to reduce thickness, then a joining process is required, but productivity is decreased
Solution Approach 1:
The patent combines the tab and tab lead into an integrated assembly where the lead is directly connected to the tab in a unified structure. This merging eliminates the need for separate joining processes between tabs and leads, allowing the entire assembly to be manufactured as one piece and reducing assembly steps, thereby maintaining high productivity while achieving reduced thickness
3Reliability
If tab leads are formed into comb-teeth shape, then connection is achieved, but layering processes become complicated, but productivity is decreased
Solution Approach 1:
The patent extracts the tab lead connection function from the cell body structure, allowing leads to be positioned independently in the space between cells rather than being integrated into the cell layers themselves. This separation simplifies the layering process by eliminating the need for complex interlayer routing and positioning, reducing manufacturing complexity while maintaining reliable electrical connections
Data Source
AI summary
A cell structure of the present invention includes first and second sheet shaped cells, each including a first electrode and a second electrode, and an insulating member arranged between the first and second sheet shaped cells. Here, the second electrode of the first sheet-shaped cell and the second electrode of the second sheet-shaped cell face each other. The first sheet shaped cell includes a tab portion extended on an XY plane to outside of the second sheet shaped cell and the second sheet shaped cell includes a tab portion extended on the XY plane to outside of the first sheet shaped cell. The second electrodes are connected through a tab lead arranged from the tab portion to the tab portion.