Electrode Assembly Tab-Lead Joint Resistance Minimization
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Solution Overview
Problem
Conventional electrode assemblies experience resistance differences between electrodes due to uneven joint forces and welding processes, leading to nonuniform operation and reduced battery lifespan, especially in large-capacity battery packs.
Innovation Solution
A stacking or stacking/folding type electrode assembly with tabs symmetrically joined to both the top and bottom of the electrode lead, minimizing resistance differences and enhancing joint forces through welding, using a metal electrode lead such as aluminum, copper, or nickel plates, and connection methods like ultrasonic or laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode tabs are joined to electrode lead in a concentrated state using conventional welding processes, then manufacturing simplicity is maintained, but resistance difference between electrodes increases and joint force uniformity deteriorates
Solution Approach 1:
The electrode tabs are segmented into multiple groups (first group and second group) that are joined to different locations on the electrode lead (top surface and bottom surface respectively). This segmentation distributes the joint forces across multiple locations, preventing concentration of stress and heat at a single welding point, thereby achieving more uniform joint forces and reduced resistance differences between electrodes.
Solution Approach 2:
The joining structure transitions from a single-plane concentrated join to a multi-dimensional distributed join. By utilizing both the top surface and bottom surface of the electrode lead, the solution adds a vertical dimension to the joining arrangement, spreading the connection points across three-dimensional space to achieve better force distribution.
2Duration of action of moving object
If conventional concentrated joining method is used, then manufacturing process is simple, but resistance difference between electrodes increases leading to reduced battery lifespan
Solution Approach 1:
The electrode tabs are divided into multiple groups that are joined to different locations on the electrode lead. This segmentation distributes the electrical current path lengths from different tabs to the lead, reducing resistance differences between electrodes and extending battery lifespan, while maintaining a relatively simple manufacturing process.
Solution Approach 2:
Different locations on the electrode lead (top surface and bottom surface) are utilized to join different groups of electrode tabs. This local differentiation optimizes the electrical connection quality at each location, ensuring uniform current distribution and reducing resistance variations that would otherwise limit battery lifespan.
3Reliability
If electrode tabs are joined at a single location on electrode lead, then manufacturing is easier, but resistance difference between electrodes increases
Solution Approach 1:
The joining process is segmented into multiple locations on the electrode lead. By joining electrode tabs at both the top surface and bottom surface of the lead rather than at a single location, the solution achieves more uniform electrical resistance across different electrode connections while maintaining manufacturing simplicity through standardized welding procedures at multiple points.
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 solution effectively minimizes resistance differences between electrodes, ensuring high reliability and extended battery life by maintaining uniform operation and increased joint forces between electrode tabs and leads.
Implementation Method 1
connection methods like ultrasonic or laser welding
Implementation Method 2
connection methods like ultrasonic or laser welding
Data Source
AI summary
Disclosed herein is a stacking or stacking/folding type electrode assembly of a cathode/separator/anode structure, wherein the electrode assembly is constructed in a structure in which tabs (electrode tabs), having no active material applied thereto, protrude from electrode plates constituting the electrode assembly, the electrode tabs are electrically connected to an electrode lead, and the pluralities of electrode tabs are joined to the top and the bottom of the electrode lead at an electrode lead-electrode tabs joint portion such that the resistance difference between electrodes at the electrode lead-electrode tabs joint portion is minimized. Also disclosed is an electrochemical cell including the electrode assembly.