Electrode Stack Layout With Non-Overlapping Tabs for Thinner Welding
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Solution Overview
Problem
The increasing welding thickness between electrode tabs or between an electrode tab and a lead terminal in secondary battery cells leads to deteriorated welding quality, increased production costs, and reduced productivity, as it affects the robustness of the weld and necessitates more frequent maintenance of welding tools.
Innovation Solution
The electrode stack employs A-type and B-type electrodes with non-overlapping tabs of different positions and widths, allowing for reduced welding thickness by alternating their stacking and using a specialized processing machine to form tabs at specific positions, thereby minimizing the number of tabs to be welded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of electrodes stacked in the cell is increased to achieve high energy density, then the energy density of the cell is improved, but the thickness of the electrode tab and welding thickness between electrode tab and lead terminal increases
Solution Approach 1:
The electrode tabs are segmented into multiple thinner tabs instead of using a single thick tab. This allows the current to be distributed across multiple welding points, reducing the welding thickness at each point while maintaining the overall current capacity needed for high energy density batteries.
Solution Approach 2:
The solution transitions from increasing tab thickness (one-dimensional approach) to increasing tab quantity and distributing welding points across two dimensions. By arranging multiple tabs in a planar distribution, the welding thickness is reduced while still achieving the required current handling capability.
2Temperature
If the welding thickness of the electrode tab is increased to reduce heat generation during quick charging, then the heat generation is reduced, but the welding quality deteriorates and production cost increases
Solution Approach 1:
The welding connection is segmented into multiple thinner welding points rather than a single thick weld. This reduces the welding thickness at each point, improving welding quality and robustness while distributing the heat generation across multiple points, thereby controlling overall heat during quick charging.
Solution Approach 2:
Multiple thin tabs act as intermediaries between the electrode and the lead terminal, distributing the electrical current and heat generation across multiple pathways. This reduces the thermal load at each welding point while maintaining overall current capacity.
Data Source
AI summary
An electrode stack and a method of manufacturing the same are proposed. The electrode stack may include an A-type electrode including an A-type tab, and a B-type electrode stacked on the A-type electrode and including a B-type tab. The A-type tab and the B-type tab may not overlap each other, and the A-type electrode and the B-type electrode may have the same polarity.