Electrode Tab Layout for Swelling-Resistant Rechargeable Batteries
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Solution Overview
Problem
Conventional rechargeable batteries face issues with durability due to stress concentration at the boundaries between the electrode base tabs and current collectors, leading to potential shorts and fractures during swelling.
Innovation Solution
The design includes electrode plates with an outermost electrode base tab having a smaller width than the remaining tabs, positioned within the inner region of the connected tabs, and a rounded boundary to disperse stress, preventing sudden shorts and fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode base tabs are connected to one another with uniform width, then the electrical connection is simplified, but stress concentration occurs at the boundaries between electrode base tabs and current collectors leading to shorts and fractures
Solution Approach 1:
The patent applies local quality by making the outermost electrode base tab narrower than the inner electrode base tabs. This creates a gradient structure where the boundary between the electrode base tab and current collector has reduced stress concentration. The localized change in width at specific positions prevents stress buildup at the boundaries while maintaining adequate width in the center for electrical connection, thereby improving durability without compromising overall structural strength.
Solution Approach 2:
The patent introduces asymmetry by designing the outermost electrode base tab with a different width compared to the inner electrode base tabs. This asymmetric configuration creates a stepped or gradient structure that distributes stress more evenly during battery swelling and contraction. The narrower outermost tabs reduce stress concentration at critical boundaries, preventing shorts and fractures while maintaining sufficient electrical connectivity.
2Ease of manufacture
If the boundary between electrode base tab and current collector is sharp, then the manufacturing process is simpler, but stress concentration leads to fractures during swelling
Solution Approach 1:
The patent applies curvature by rounding the boundary between the electrode base tab and current collector instead of using a sharp corner. This rounded transition distributes stress more evenly during battery swelling and contraction cycles, preventing stress concentration at the boundary. The curved geometry maintains manufacturing feasibility while significantly improving fracture resistance and overall reliability of the electrode assembly.
3Device complexity
If the outermost electrode base tab has the same width as inner tabs, then the structure is uniform and easier to manufacture, but stress cannot be dispersed during swelling leading to shorts
Solution Approach 1:
The patent resolves this contradiction by applying local quality - making the outermost electrode base tab narrower than the inner tabs. This localized width reduction creates a gradient structure that disperses stress during swelling while maintaining adequate width in the center for electrical connection. The asymmetric design prevents stress concentration at boundaries without requiring complete structural redesign, balancing manufacturing simplicity with improved reliability.
Data Source
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AI summary
A rechargeable battery according to the present disclosure includes an electrode assembly including a plurality of electrode plates, each electrode plate including an electrode base tab and disposed to be stacked on one another, and a separator interposed between the plurality of electrode plates, and a case accommodating the electrode assembly, wherein a width of an electrode base tab of an outermost electrode plate in the electrode assembly is smaller than a width of the electrode base tab of each of the remaining electrode plates.