Cylindrical Electrode Assembly With Radial Bent Tabs for Low Resistance
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Solution Overview
Problem
Conventional cylindrical batteries face issues with current collection efficiency due to concentrated current flow in strip-shaped electrode tabs, leading to high resistance and heat generation, especially when scaled for electric vehicles, and the design complicates electrolyte injection and welding processes.
Innovation Solution
The electrode assembly features uncoated portions at both ends bent in a radial direction, forming a structured bending surface with a minimum of 10 overlapping layers, ensuring easy welding and preventing separator damage, while maintaining an open electrolyte passage and reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a battery module includes batteries arranged in an array and connected in parallel, then the current capacity is improved, but the module width increases
Solution Approach 1:
The patent transitions from a planar array arrangement to a three-dimensional stacked configuration. Multiple batteries are arranged in layers along the width direction, with insulating plates separating the layers. This vertical stacking approach increases current capacity by adding more batteries without proportionally increasing the module width, as the expansion occurs primarily in the thickness direction rather than the width direction.
2Reliability
If insulating plates are arranged between battery stacks to prevent contact, then short circuit risk is reduced, but the number of parts increases
Solution Approach 1:
The insulating plates are integrated into the battery module structure as essential structural components rather than separate protective elements. Each insulating plate is positioned between adjacent battery stacks and serves dual functions: preventing electrical short circuits and providing structural support for the layered configuration. This merging approach ensures reliability through short circuit prevention while minimizing the increase in part count by making the insulating plates integral to the module's structural framework.
3Volume of moving object
If batteries are arranged in a three-dimensional stacked configuration, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The battery module is segmented into discrete layers, with each layer containing a specific arrangement of batteries and insulating plates. This segmentation allows for standardized manufacturing of individual layers that can be assembled through stacking. The repetitive modular structure simplifies the manufacturing process compared to creating complex three-dimensional arrangements, as each layer can be produced using similar procedures and then stacked to form the complete module, thereby improving space utilization without proportionally increasing manufacturing complexity.
Data Source
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AI summary
Disclosed is an electrode assembly, a battery, and a battery pack and a vehicle including the same. At least one of the first electrode and the second electrode includes an uncoated portion at a long side end, a part of the uncoated portion is exposed to the outside of the separator along a longitudinal direction of the electrode assembly, at least a part of the uncoated portion is bent in a radial direction of the electrode assembly to form a bending surface, and the bending surface may include a region in which the number of overlapping layers of the uncoated portion is substantially kept constant as a criterion layer number along the radial direction The welding region of the current collecting plate welded to the bending surface may overlap with the region in which the number of overlapping layers of the uncoated portion is kept as the criterion layer number.