Clinched Electrode Tab-Lead Assembly With Plastic Burr Protection
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Solution Overview
Problem
Existing electrode assemblies face issues with unstable coupling between electrode tabs and leads, leading to damage of the battery case due to protruding burrs and potential separation or cutting of electrode tabs during welding, which affects the reliability and safety of secondary batteries.
Innovation Solution
The electrode assembly employs a clinching method to couple electrode tabs to an electrode lead that wraps both the upper and lower surfaces of the tabs, using an electrode lead with a bent structure and optionally a plastic member to prevent damage and improve coupling strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to couple electrode tabs to electrode leads, then electrical connection is achieved, but electrode tabs may be cut or separated due to unstable coupling
Solution Approach 1:
A plastic member is introduced as an intermediary component between the electrode tab and electrode lead. This plastic member wraps around the electrode tab and is coupled to the electrode lead, distributing the mechanical stress and preventing direct concentration of force on the tab-lead interface, thereby preventing tab cutting or separation while maintaining electrical connection
Solution Approach 2:
The coupling structure combines multiple materials: the electrode lead (conductive), electrode tab (conductive), and plastic member (insulating and structurally supportive). This composite approach leverages the strengths of each material - the conductive materials provide electrical connection while the plastic member provides mechanical protection and stress distribution
2Reliability
If electrode tabs are coupled to electrode leads, then electrical connection is established, but burrs may damage the battery case
Solution Approach 1:
The plastic member serves as a protective intermediary that covers the burrs on the electrode tab surface. By wrapping around the tab, it creates a smooth outer surface that contacts the battery case, preventing burr-induced damage while allowing the underlying tab-lead connection to maintain electrical functionality
Solution Approach 2:
The plastic member transforms the harmful protruding burrs into a beneficial protective feature. The burrs that would normally damage the battery case are now covered and protected by the plastic member, which can be designed with appropriate thickness and material properties to absorb or distribute the mechanical contact stresses
3Object-affected harmful factors
If a plastic member is added to protect the coupling portion, then battery case damage is prevented, but device complexity increases
Solution Approach 1:
The plastic member is implemented as a thin-wrapped shell structure that conformally covers the electrode tab and coupling region. This thin-film approach provides protective functionality without adding significant bulk or complexity to the overall battery structure, maintaining simplicity while achieving the protective function
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 reliability of the coupling by preventing tab damage and battery case harm, while maintaining a stable connection, thus improving the safety and durability of secondary batteries.
Implementation Method 1
the electrode tabs are coupled to the electrode lead by clinching
Data Source
AI summary
An electrode assembly has a structure in which a plurality of electrodes, from each of which an electrode tab protrudes, is stacked, wherein the electrodes are coupled to each other by welding the electrode tabs to each other, the electrode tabs are coupled to an electrode lead, the electrode lead wraps the electrode tabs by including an electrode lead main body with a first surface coupled to the upper surface of the electrode tabs, a second surface bent at a first bent portion in a state of being connected to the first surface so as to be coupled to a lower surface of the electrode tabs, and a third surface bent at a second bent portion in a state of being connected to the second surface and configured to be withdrawn outside a battery case, and the electrode tabs are coupled to the electrode lead by clinching.