Composite-Substrate Battery Electrodes With Joined Conductor Tabs
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Solution Overview
Problem
Existing secondary batteries face challenges in reducing weight while maintaining safety and energy density, particularly in portable devices and vehicles, as thinning materials and increasing energy density can compromise safety.
Innovation Solution
A secondary battery design featuring a composite substrate with polymer and metal layers on both sides, where electrode plates have active and non-coated portions, and conductors are joined between these non-coated areas, secured by fixing members such as rivets or adhesives, to enhance electrical connection and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If materials such as substrates, separators, and outer materials are thinned to reduce weight, then weight is reduced, but safety is compromised
Solution Approach 1:
The substrate uses a composite structure combining polymer material and aluminum alloy material, where the polymer layer provides flexibility and weight reduction while the aluminum alloy layers provide structural strength and safety, resolving the contradiction between weight reduction and safety maintenance
2Quantity of substance
If energy density is increased by improving physical properties of active materials, then energy density is improved, but safety is reduced
Solution Approach 1:
The composite substrate structure allows for optimized active material loading while maintaining structural integrity through the aluminum alloy reinforcement layers, enabling higher energy density without compromising safety
Solution Approach 2:
The substrate has different properties in different regions - the polymer regions provide flexibility and weight reduction while the aluminum alloy regions provide localized structural support and safety, allowing optimized energy density distribution
3Reliability
If conductors are joined to electrode assembly for electrical connection, then electrical conductivity is improved, but device complexity increases
Solution Approach 1:
The conductor joining process integrates multiple functions into a single operation - mechanical attachment, electrical connection, and positioning are achieved simultaneously through the joining member that connects conductors to electrode plates at non-coated portions, reducing overall device complexity
Data Source
AI summary
Disclosed is a secondary battery and a method for manufacturing the same. The secondary battery includes an electrode assembly including a plurality of electrode plates, and a plurality of conductors joined to the electrode assembly, in which each of the plurality of electrode plates includes a portion with an active material on both sides of a composite substrate, and a non-coated portion free of the active material, and where one end of each of the plurality of conductors is arranged between two adjacent non-coated portions of the plurality of electrode plates.