Integrated Electrode Tab Bundle With Melted Through-Hole Connector
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Solution Overview
Problem
Existing electrode assembly manufacturing methods face challenges in forming electrode tab bundles without contamination and ensuring safety against short circuits and explosions, particularly due to the difficulty in coupling electrode tabs using conventional welding methods and the risk of impurities causing contamination.
Innovation Solution
An electrode assembly is designed with electrode tabs stacked and through-holes formed, allowing a low-melting-point connection member to be inserted and melted for electrical connection to the electrode lead, reducing the risk of contamination and enabling separation during thermal events to prevent explosions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods (ultrasonic welding or laser welding) are used to couple electrode tabs, then electrical connection between tabs can be achieved, but the coupling portion becomes contaminated by impurities generated during welding
Solution Approach 1:
A connection member made of low-melting-point material is introduced as an intermediary between the electrode tabs. This connection member melts at a lower temperature than the electrode tabs, creating a eutectic structure that provides reliable electrical connection without requiring high-temperature welding that generates impurities. The connection member acts as a mediator that achieves electrical connectivity while avoiding the harmful effects of conventional welding methods.
2Reliability
If electrode current collector with insulation layer is used to prevent short circuits, then safety against short circuits is improved, but it becomes difficult to form electrode tab bundle by conventional welding methods
Solution Approach 1:
The invention changes the melting point parameter of the connection material by using a low-melting-point material (such as solder or eutectic alloy) instead of relying on conventional welding methods. This parameter change allows the connection to be made at lower temperatures that do not damage the insulation layer, thereby enabling tab bundle formation while maintaining the short-circuit prevention function of the insulation layer.
3Reliability
If low-melting-point metal is inserted through through-holes and heating is performed to achieve electrical connection, then electrical connection between electrode tabs is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention merges multiple functions into the connection member: it provides mechanical bonding between tabs, establishes electrical connectivity, and enables thermal release in emergency situations. By combining these functions into a single component made of low-melting-point material, the overall device complexity is reduced compared to using separate components for each function.
4Reliability
If electrode lead and electrode tab bundle are coupled using welding method, then electrical connection is achieved, but the coupling portion is contaminated by impurities generated during welding
Solution Approach 1:
The low-melting-point connection member serves as an intermediary between the electrode lead and tab bundle, enabling electrical connection through melting and bonding rather than through welding processes that generate impurities. This intermediary approach eliminates the contamination problem while maintaining reliable electrical connectivity.
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
This method simplifies the manufacturing process, reduces weight, enhances energy density, and prevents ignition and explosion risks by ensuring reliable electrical connections and easy separation of the electrode lead and tab bundle during overheating.
Implementation Method 1
a connection member made of an electrically conductive material is inserted through the through-hole, and an electrode lead is electrically connected to the electrode tab bundle via the connection member in a melted state
Data Source
AI summary
The present invention relates to an electrode assembly including a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode, wherein an electrode tab protrudes from at least an outer periphery of one side of each of a plurality of positive electrodes and a plurality of negative electrodes, the electrode tabs being coupled to each other in tight contact in a stacking direction to constitute an electrode tab bundle, at least one through-hole is formed through the electrode tab bundle, a connection member made of an electrically conductive material is inserted through the through-hole, and an electrode lead is electrically connected to the electrode tab bundle via the connection member in a melted state, and wherein electrical connection between the electrode tab bundle and the electrode lead is achieved by heating and pressing.