Selective Insulating Coating on Electrode Tabs for Lead Welding

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Solution Overview

Problem

Conventional pouch-shaped lithium secondary batteries face high defect rates and complex manufacturing processes due to non-uniform insulating layers between electrode tabs and leads, which can lead to short circuits and increased weldability issues.

Innovation Solution

An electrode with an insulating layer formed by coating on the electrode tab, allowing for improved weldability and reduced defect rates by simplifying the coating and welding processes, where the insulating layer is applied on one surface of the electrode tab and not on the surface welded to the electrode lead, enhancing electrical insulation and preventing short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulating layer is applied on the electrode tab surface to be welded to the electrode lead, then electrical insulation is improved, but weldability deteriorates and welding defect rate increases

Engineering Contradiction:

Improveelectrical insulationVSAvoidweldability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulating layer is applied selectively only on specific surfaces of the electrode tab (top, bottom, and side surfaces) while deliberately excluding the welding surface. This local differentiation allows the electrode tab to have both electrical insulation where needed and good weldability where required, resolving the contradiction between these two requirements.

Inventive Principle:

Principle #3Local quality

2Reliability

If an insulating layer is applied uniformly on all surfaces of the electrode tab, then electrical insulation is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveelectrical insulationVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrode tab surface is segmented into two functional zones: insulating surfaces (top, bottom, sides) and a non-insulating welding surface. This segmentation allows the insulating layer to be applied only where electrical insulation is needed, simplifying the manufacturing process compared to uniform coverage while maintaining adequate insulation protection.

Inventive Principle:

Principle #1Segmentation

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 significantly reduces welding defect rates and simplifies the manufacturing process, improving the safety and reliability of lithium secondary batteries by enhancing weldability and preventing short circuits.

Implementation Method 1

an insulating layer formed by coating on the electrode tab

Methodology Applied

Scientific EffectCoating: Coatings

Implementation Method 2

welded to an electrode lead

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20230352801A1Electrode Having Excellent Weldability Between Electrode Lead and Electrode Tab and Method of Manufacturing the Same

Publication Date: 2023.11.02 LG ENERGY SOLUTION LTD

AI summary

A battery includes an electrode tab coated with an insulating layer, and more particularly to an electrode including an electrode current collector coated with an electrode active material, an electrode tab protruding from the electrode current collector, and an insulating layer formed on the electrode tab by coating, wherein the other surface of the electrode tab having the insulating layer formed thereon by coating is welded to an electrode lead.