Curved Electrode Tab Bundle Structure to Prevent Swelling Breakage
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Solution Overview
Problem
Existing electrode assemblies in pouch-shaped battery cells are vulnerable to breakage due to stress in both the longitudinal and thickness directions, particularly during swelling and movement, as the electrode tabs lack sufficient length margin.
Innovation Solution
The electrode assembly is designed with a tab bundle structure that includes convex and concave portions successively formed along the electrode tabs, and a forming apparatus with guide portions that bend and pre-weld the tabs to secure length margin in both directions, minimizing breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrode tabs are arranged in a straight line without separate shape, then manufacturing process is simple, but electrode tabs are vulnerable to breakage during swelling and movement
Solution Approach 1:
The patent applies curvature to the electrode tabs by forming convex and concave portions along the tab length. This curved structure allows the tabs to flex and absorb stress during battery swelling and movement, preventing breakage while maintaining manufacturing feasibility through standard forming processes
2Productivity
If electrode tabs are pre-welded in straight configuration, then assembly process is efficient, but tabs cannot accommodate stress from movement and swelling
Solution Approach 1:
The patent applies preliminary action by forming the convex and concave portions in the electrode tabs before the welding process. This pre-forming of the curved structure allows the tabs to have stress-accommodating geometry ready before assembly, enabling both efficient pre-welding and subsequent stress resistance during battery operation
Data Source
AI summary
The present invention relates to an electrode assembly configured such that a separator is interposed between a plurality of electrodes each having an electrode tab protruding therefrom and the electrode tabs are stacked to form a tab bundle, wherein a convex portion and a concave portion are successively formed at the tab bundle so as to extend in a longitudinal direction of the electrodes. The convex portion and the concave portion formed at the tab bundle ensure the length margin of the electrode tabs to prevent tab breakage.