Electrode Assembly with Variable Tab Lengths for Stable Joint Portions
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Solution Overview
Problem
Conventional electrode assemblies experience structural instability and increased risk of short circuits due to varying contact areas between electrode tabs and leads, leading to the necessity for oversized leads and additional cutting processes, which complicate the assembly and increase the risk of mechanical stress-induced errors.
Innovation Solution
A stacking or stacking/folding type electrode assembly with electrode tabs of varying lengths that are gradually increased to match the distance between electrode leads, minimizing bending and ensuring consistent joint lengths, while using metal electrode leads connected via welding for stable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode tabs are joined in a concentrated state with varying lengths, then electrical connection is achieved, but structural stability deteriorates and short circuit risk increases
Solution Approach 1:
The patent applies local quality by making each electrode tab have a different length according to its position in the stack. Tabs closer to the lead have shorter lengths, while tabs farther away have longer lengths, optimizing each tab's contribution to electrical connection while maintaining overall structural stability.
Solution Approach 2:
The patent implements asymmetry by deliberately creating unequal lengths among electrode tabs. This asymmetric design allows tabs to be optimally positioned at different distances from the lead, improving electrical connection reliability while preventing the structural instability that would result from concentrated joining of uniformly sized tabs.
2Reliability
If oversized electrode leads are used to accommodate varying tab contact areas, then electrical connection is ensured, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent uses local quality to match each tab's contact area with its specific position requirements. By varying tab lengths locally rather than using a uniform oversized lead, the design achieves reliable electrical connection without the need for excessively large leads, thereby reducing device complexity.
3Manufacturing precision
If additional cutting processes are implemented to trim electrode tabs, then uniform contact areas are achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent applies preliminary action by pre-determining the optimal lengths of electrode tabs during the manufacturing process. Instead of requiring post-assembly cutting to achieve uniformity, the tabs are initially formed with their final required lengths, eliminating additional cutting processes and improving productivity.
4Manufacturing precision
If electrode tabs are bent to reduce length differences, then joint portion consistency is improved, but mechanical stress and potential errors increase
Solution Approach 1:
The patent inverts the conventional approach by not bending the tabs to achieve consistency, but rather making the tabs inherently different lengths from the start. This inversion eliminates the need for bending operations that would introduce mechanical stress, while still achieving consistent joint portions through proper positioning.
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
The solution stabilizes the electrode assembly by maintaining consistent joint lengths and reducing lead size, minimizing the risk of short circuits and burrs, thus enhancing structural integrity and assembly efficiency.
Implementation Method 1
electrode leads are located at one-side ends of the stacked electrode tabs such that the electrode leads are electrically connected to the electrode tabs
Data Source
AI summary
Disclosed herein is a stacking or stacking/folding type electrode assembly of a cathode/separator/anode structure, wherein the electrode assembly is constructed in a structure in which tabs (electrode tabs), having no active material applied thereto, protrude from electrode plates constituting the electrode assembly, electrode leads are located at one-side ends of the stacked electrode tabs such that the electrode leads are electrically connected to the electrode tabs, and protruding lengths of the electrode tabs are gradually increased according to the distances between the electrode leads and the electrode tabs, whereby the lengths of the electrode tabs at joint portions between the electrode tabs and the electrode leads are the same. Also disclosed is an electrochemical cell including the electrode assembly.