Battery Electrode Tab Bonding With Conductive Cover Tape
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Solution Overview
Problem
Existing secondary battery manufacturing methods face issues with insufficient welding area for electrode tabs, leading to stress concentration, crack formation, and potential short circuits due to welding, which can cause performance deterioration and safety risks.
Innovation Solution
The use of a cover tape with an insulating adhesive and conductive particles to connect the electrode tab and terminal plate through heat, laser, or ultrasonic compression, ensuring a larger contact area and stable electrical connection while preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding method is used to join electrode tab to terminal plate, then electrical connection is achieved, but welding area is insufficient causing stress concentration and crack formation
Solution Approach 1:
The patent merges the functions of electrical connection and mechanical joining into a single cover tape component. The cover tape simultaneously provides adhesive bonding for mechanical strength and conductive particles for electrical conductivity, eliminating the need for separate welding operations and distributing stress over a larger area.
Solution Approach 2:
The cover tape is constructed as a composite material containing both adhesive components (for bonding) and conductive particles (for electrical conductivity). This composite structure allows the single component to fulfill multiple functions: mechanical joining, electrical connection, and stress distribution, resolving the contradiction between connection reliability and joining strength.
2Reliability
If welding is performed on electrode tab, then electrical connection is established, but cracks and short circuits may occur due to stress concentration
Solution Approach 1:
The cover tape acts as an intermediary component between the electrode tab and terminal plate. Instead of directly welding the tab to the terminal plate (which causes stress concentration), the cover tape mediates the connection, distributing mechanical stress through its adhesive layer and providing electrical conductivity through embedded particles, thereby preventing crack formation and short circuits.
Solution Approach 2:
The invention changes the connection method from direct welding (high stress, localized) to adhesive bonding with conductive particles (distributed stress, larger area). This parameter change in the joining mechanism transforms the stress distribution pattern, reducing peak stresses that lead to crack formation while maintaining electrical conductivity.
3Strength
If welding area is increased to prevent stress concentration, then joining strength improves, but manufacturing complexity increases
Solution Approach 1:
The cover tape is designed as a pre-fabricated component with conductive particles distributed throughout its structure. This segmentation of the connection function into a dedicated component simplifies the manufacturing process, as the cover tape can be applied as a single unit rather than requiring complex welding operations to achieve adequate joining strength.
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
Improves the joining strength and electrical conductivity between the electrode tab and terminal plate, reducing the risk of cracks and short circuits, enhancing the battery's performance and safety.
Implementation Method 1
The cover tape may be heat-compressed, laser-compressed, or ultrasonically compressed between the electrode tab and the terminal plate, the conductive particles electrically connecting the electrode tab and the terminal plate.
Implementation Method 2
The cover tape may be heat-compressed, laser-compressed, or ultrasonically compressed between the electrode tab and the terminal plate, the conductive particles electrically connecting the electrode tab and the terminal plate.
Implementation Method 3
The cover tape may be heat-compressed, laser-compressed, or ultrasonically compressed between the electrode tab and the terminal plate, the conductive particles electrically connecting the electrode tab and the terminal plate.
Implementation Method 4
Joining the electrode tab to the terminal plate may include heat-compressing, laser-compressing, or ultrasonically compressing the cover tape between the electrode tab and the terminal plate, the adhesive portion joining the electrode tab and the terminal plate.
Implementation Method 5
Joining the electrode tab to the terminal plate may include heat-compressing, laser-compressing, or ultrasonically compressing the cover tape between the electrode tab and the terminal plate, the adhesive portion joining the electrode tab and the terminal plate.
Implementation Method 6
Joining the electrode tab to the terminal plate may include heat-compressing, laser-compressing, or ultrasonically compressing the cover tape between the electrode tab and the terminal plate, the adhesive portion joining the electrode tab and the terminal plate.
Data Source
AI summary
A secondary battery, including an electrode assembly configured by winding a first electrode, a second electrode, and a separator provided between the first electrode and the second electrode, a case having an opening on one side, the case accommodating the electrode assembly therein, an electrode tab joined to the first electrode, a cap assembly joined to the one side of the case to seal the opening, the cap assembly including a terminal plate electrically connected to the first electrode, and a cover tape covering a first side of the electrode tab adjacent to the terminal plate, the cover tape electrically connecting and joining the electrode tab and the terminal plate.