Non-Coated Electrode Tab Layout for Safer Battery Welding
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Solution Overview
Problem
In secondary batteries, particularly pouch-shaped batteries, the increased number of stacked electrode layers leads to poor welding of non-coated electrode tabs, resulting in welding defects and potential cutting of tabs during ultrasonic or laser welding, which affects the battery's performance and reliability.
Innovation Solution
The provision of one or more non-coated electrode tabs for a plurality of stacked electrodes with the same polarity, arranged to alternately overlap and coupled to an electrode lead without exceeding its width, with a sonotrode horn featuring a rounded protrusion-type unit pitch pattern for improved welding, reduces the thickness of the tabs and enhances welding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of stacked electrode layers is increased to achieve high output and capacity, then the battery's output and capacity are improved, but the welding quality of electrode tabs deteriorates due to excessive thickness
Solution Approach 1:
The patent divides the thick electrode assembly into multiple segments by providing non-coated electrode tabs at different positions (first non-coated electrode tab at the first position, second non-coated electrode tab at the second position) rather than having a single thick tab structure. This segmentation allows each tab to be welded separately with controlled thickness, resolving the welding quality issue while maintaining high capacity through multiple layers.
Solution Approach 2:
The patent applies different properties to different parts of the electrode structure. Specifically, certain electrode tabs are left non-coated (without protective coating) at specific positions to enable better welding contact, while other portions maintain their coating for protection. This local differentiation of properties allows optimized welding at critical interfaces while preserving overall electrode integrity.
2Productivity
If ultrasonic or laser welding is used to weld thickened electrode tabs, then welding speed is maintained, but welding defects increase and electrode tabs may be damaged or cut
Solution Approach 1:
The patent changes the physical parameters of the electrode tabs by leaving them non-coated at specific positions, which alters their thermal and mechanical properties during welding. This parameter change enables better energy distribution during ultrasonic or laser welding, preventing excessive heat concentration that would cause tab cutting or damage, while maintaining welding speed through efficient energy transfer.
3Quantity of substance
If multiple non-coated electrode tabs are welded to form electrical conduction path, then electrical conductivity is improved, but welding safety deteriorates due to poor welding quality
Solution Approach 1:
The patent segments the electrode tab structure into multiple non-coated tabs positioned at different locations (first position, second position) rather than using a single thick tab. This segmentation reduces the thickness of each individual tab that needs to be welded, improving welding quality and safety while maintaining electrical conductivity through the distributed tab structure.
Solution Approach 2:
The non-coated electrode tabs act as intermediaries between the electrode plates and the external circuit. By providing multiple non-coated tabs at different positions, the patent creates intermediate welding interfaces that are easier to weld safely, mediating the connection between thick electrode assemblies and external leads while maintaining electrical conduction.
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
This configuration prevents tab cutting and ensures uniform welding strength distribution, reducing welding defects and improving the overall performance and reliability of the secondary battery by maintaining consistent welding time and amplitude.
Implementation Method 1
coupled to an electrode lead... with a sonotrode horn featuring a rounded protrusion-type unit pitch pattern for improved welding
Implementation Method 2
The positive electrode tabs and the negative electrode tabs are coupled respectively to a positive electrode lead and to a negative electrode lead using an ultrasonic welding machine
Data Source
AI summary
Disclosed herein are an electrode having improved electrode tab welding characteristics configured such that one or more non-coated electrode tabs are provided for a plurality of stacked electrodes having the same polarity in order to maintain welding safety in the case in which the number of electrode layers that are stacked is increased in order to achieve high output and capacity, and a secondary battery including the same. Consequently, it is possible to prevent a plurality of electrode tabs from being cut at the time of welding the electrode tabs. In addition, the lower end of an electrode lead that is welded to non-coated electrode tabs provided for a plurality of stacked electrodes having the same polarity is punched so as to correspond to the non-coated electrode tabs. Consequently, it is possible to improve flexibility for a step formed in the secondary battery electrode.