Electrode Assembly Tab-Lead Coupler Design for Battery Energy Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current secondary battery designs, particularly lithium secondary batteries, face challenges in enhancing energy density due to structural limitations, especially with the volume occupied by electrode tabs and tab-lead couplers, which hinder the expansion of battery capacity.
Innovation Solution
The electrode assembly is enhanced by bending electrode tabs and positioning the tab-lead coupler on the outermost electrode plate or its extension line, reducing the occupied space and improving energy density without modifying existing manufacturing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrode tabs and tab-lead coupler are positioned in conventional locations, then electrical connection is ensured, but volume occupied by these components increases, reducing energy density
Solution Approach 1:
The electrode tabs are bent from their conventional planar arrangement into a three-dimensional folded configuration. This dimensional transformation allows the tabs to occupy less space within the battery cell while maintaining their electrical connection function, thereby increasing energy density without compromising structural integrity
Solution Approach 2:
The bent electrode tabs are positioned and secured within the battery case structure, effectively nesting them into the available space. The tab-lead coupler is similarly integrated into the battery case, allowing these components to occupy minimal volume while maintaining their functional requirements
2Volume of stationary object
If electrode tabs are bent to reduce space, then volume occupied is reduced, but structural stability and risk of internal shorts may be compromised
Solution Approach 1:
The electrode tabs are pre-bent into their final folded configuration before assembly into the battery case. This preliminary action ensures that the tabs maintain their bent shape and proper positioning throughout assembly, preventing structural instability or contact with other components that could cause internal shorts
Solution Approach 2:
The battery case serves as an intermediary structure that houses and secures the bent electrode tabs and tab-lead coupler. This intermediary component provides mechanical support and isolation, ensuring that the bent tabs maintain their shape and do not come into contact with other battery components, thereby preventing internal shorts
Data Source
AI summary
Disclosed is a battery cell, including an electrode assembly including electrode plates respectively having an electrode tab protruding therefrom and separators, which are alternately stacked, the electrode tabs being bent in an upper direction of the electrode assembly, the electrode assembly including an electrode lead coupled with an end of the bent electrode tabs to form a tab-lead coupler; and a battery case configured to accommodate the electrode assembly so that the electrode lead is partially exposed outwards. The tab-lead coupler is located on an extension line of an outermost electrode plate of the electrode assembly, which is located at a side where the electrode tabs are bent, and the tab-lead coupler is opposite to one side of the electrode assembly having the protruded electrode tab to come into contact with one side of the electrode assembly or be spaced apart therefrom.