Electrode Assembly Tab Gathering via Separator Edge Sealing
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Solution Overview
Problem
Existing secondary battery manufacturing processes face issues with non-uniform gathering of electrode tabs, potential damage to electrodes and tabs, and risk of disconnection due to tab guides and welding vibrations.
Innovation Solution
An electrode assembly design where separators with protruding edge portions are used to seal the electrode tabs together, allowing them to be gathered without a tab guide, and a manufacturing method that involves stacking electrodes, and a sealing tool 400 to be described later. The separators include an electrode assembly and a sealing tool 400 to be described later. The separators include polypropylene and/or polyethylene. Additionally, the separator 200 may include materials such as polymer composite, polyvinyl alcohol, polyester, and polyamide. The description of the material of the separator 200 described above is an example and is not limited to the above. The material of the separator 200 may be sealed by heating and pressurizing using a sealing tool 400 to be described later.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tab guides are used to gather electrode tabs during welding, then electrode tabs can be gathered for welding, but the electrode tabs may not be gathered uniformly and electrodes, separators, or electrode tabs may be damaged
Solution Approach 1:
The separator's edge portion serves as an intermediary element between the tab guide and the electrode tabs. Instead of the tab guide directly contacting and potentially damaging the electrode tabs, the separator's edge portion acts as a protective mediator that guides the tabs while preventing direct mechanical contact that could cause damage. The separator material itself becomes the gathering mechanism, eliminating the need for separate tab guides.
Solution Approach 2:
The separator performs a dual function: it separates electrodes (its primary function) and it gathers electrode tabs (secondary function). By utilizing the separator's own structure (edge portion protruding beyond electrode edges) to perform the gathering function, the invention eliminates the need for separate tab guiding components. The separator serves itself by structurally enabling both separation and gathering functions simultaneously.
2Ease of manufacture
If tab guides are used to gather electrode tabs, then welding can be performed, but disconnection or tearing of electrode tabs may occur due to welding vibrations
Solution Approach 1:
The separator's edge portion provides beforehand cushioning by creating a protective barrier that absorbs and distributes welding vibrations before they can reach the electrode tabs. The separator material acts as a cushioning layer that mitigates the impact of vibrations during the welding process, preventing disconnection or tearing of the tabs while still allowing the welding operation to proceed.
Solution Approach 2:
The separator, being a thin film structure, flexibly accommodates welding vibrations while maintaining the gathered position of electrode tabs. The flexibility of the separator material allows it to absorb vibrational energy without rigidly constraining the tabs, thereby preventing stress concentration that could lead to disconnection or tearing during welding.
3Manufacturing precision
If edge portions of separators are sealed to gather electrode tabs, then uniform gathering is achieved, but additional sealing process is required
Solution Approach 1:
The invention merges the separator edge portion sealing with the electrode tab gathering function into a single integrated process. By sealing the edge portions of adjacent separators together, the structure automatically creates a gathering mechanism that holds electrode tabs in uniform alignment. This combines the sealing operation with the tab gathering function, eliminating the need for separate tab guiding components and reducing overall device complexity.
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 ensures uniform gathering and prevents damage to electrodes and electrode tabs, reducing the risk of short circuit and disconnection defects during welding.
Implementation Method 1
The material of the separator 200 may be sealed by heating and pressurizing using a sealing tool 400
Implementation Method 2
The material of the separator 200 may be sealed by heating and pressurizing using a sealing tool 400
Data Source
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AI summary
An electrode assembly according to an embodiment of the present disclosure may include a plurality of electrodes stacked on top of each other; a plurality of separators interposed between the plurality of electrodes; and a plurality of electrode tabs connected to the plurality of electrodes and protruding further outward than the plurality of separators. Each separator may include an edge portion that protrudes further than the electrode in the extension direction of the electrode tab and partially overlaps with the electrode tab in the stacking direction of the plurality of electrodes. The edge portions of at least some of the plurality of separators may be sealed to each other so that the plurality of electrode tabs are gathered together.