Electrode Tab Guard Structure for Impact-Protected Battery Assemblies

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Solution Overview

Problem

Current collectors in electrode assemblies of secondary batteries are vulnerable to deformation and damage from external impacts, particularly when an impact is applied in the length direction, leading to potential breakage at the junction of the electrode tab and current collector.

Innovation Solution

An electrode assembly protection combination structure is introduced, featuring a guard structure with fixing portions and support portions that include slit grooves, metal portions, and elastic elements to secure and support the electrode tabs, preventing damage from external impacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the current collector is made from a thin metal foil to reduce weight and improve flexibility, then the weight and flexibility are improved, but the strength and resistance to impact damage deteriorate

Engineering Contradiction:

Improveweight of current collectorVSAvoidstrength of current collector

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent introduces a guard structure including a guard plate and buffer member positioned between the electrode assembly and external environment. The buffer member specifically cushions impacts before they reach the thin current collector, allowing the use of lightweight thin foil while preventing impact-induced damage through pre-positioned protective elements

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If the current collector is made from a thin metal foil to improve flexibility and ease of winding, then the flexibility and ease of manufacture are improved, but the reliability under external forces deteriorates

Engineering Contradiction:

Improveease of winding current collectorVSAvoidreliability of current collector

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The guard structure with buffer member is pre-installed to cushion external impacts before they affect the thin current collector, maintaining reliability while allowing the collector to remain thin for ease of winding and manufacturing

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The guard plate and buffer member act as intermediary protective elements between external forces and the thin current collector, mediating the impact forces and protecting the vulnerable thin foil structure during handling and operation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If a guard structure is added to protect the electrode assembly from impacts, then the strength and reliability are improved, but the device complexity increases

Engineering Contradiction:

Improveprotection of electrode assemblyVSAvoidcomplexity of electrode assembly structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The protection system is segmented into distinct functional components: a guard plate for structural support, a buffer member for impact absorption, and positioning protrusions for precise placement. This segmentation allows each component to perform its specific function efficiently while maintaining overall simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The buffer member is designed as a thin-walled hollow structure that provides effective impact cushioning while minimizing added mass and complexity. The thin-film-like buffer member absorbs impacts without requiring thick or complex protective layers

Inventive Principle:

Principle #30Flexible shells and thin films

4Weight of moving object

If the buffer member is designed with a thin-walled hollow structure to reduce weight, then the weight is reduced, but the resistance to deformation under impact deteriorates

Engineering Contradiction:

Improveweight of buffer memberVSAvoidresistance to impact force

Core Design Contradiction:

Weight of moving objectVSForce

Solution Approach 1:

The thin-walled hollow buffer member utilizes the shell structure effect where a thin hollow form provides disproportionate strength-to-weight ratio. The hollow structure absorbs impact energy through controlled deformation while maintaining low weight, effectively resisting impact forces without requiring thick solid material

Inventive Principle:

Principle #30Flexible shells and thin films

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 guard structure effectively protects the current collector and electrode tabs by absorbing and dissipating external forces, enhancing assembly convenience and reducing the risk of damage during handling and use.

Implementation Method 1

an elastic portion that surrounds an outer surface of the metal portion, and brings the electrode tab into contact with the metal portion

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentEP4685992A1Electrode assembly protection coupler and secondary battery including same

Publication Date: 2026.01.28 LG ENERGY SOLUTION LTD

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AI summary

The present disclosure relates to an electrode assembly protection combination structure, and there is provided the electrode assembly protection combination structure including an electrode assembly including a pair of electrode tabs; and a guard structure coupled to the electrode assembly, and configured to protect the electrode assembly from an impact, wherein the guard structure includes a pair of fixing portions configured to fix the pair of electrode tabs, respectively; and a support portion configured to support the pair of fixing portions.