Folded Electrode Tab Layout for Compact Battery Packs
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Solution Overview
Problem
The increasing demand for larger capacity and higher energy density in secondary batteries has led to larger battery cell sizes, resulting in an overall increase in the size of battery packs, which is undesirable for compact applications.
Innovation Solution
The battery pack design incorporates a battery cell with an electrode assembly and an electrode tab, along with a protection circuit module featuring a substrate and substrate tab, where the electrode tab includes a bendable electrode sealing unit and bending units to reduce the overall length and size of the battery pack while maintaining high energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cell size is increased to increase energy density, then capacity is improved, but overall size of battery pack increases
Solution Approach 1:
The electrode tab is bent at multiple angles (first bending part, second bending part, third bending part) to change its spatial configuration from a straight extension to a three-dimensional folded structure. This allows the battery pack to achieve larger capacity through optimized cell arrangement while maintaining compact overall dimensions by utilizing vertical and lateral space efficiently.
Solution Approach 2:
The protection circuit module is positioned within the space created by the bent electrode tab structure. The substrate of the protection circuit module is located between the first bending part and the electrode assembly, effectively nesting the protection circuit within the battery cell structure rather than adding it as a separate external component.
2Quantity of substance
If battery cell size is increased to increase energy density, then capacity is improved, but length of battery pack increases
Solution Approach 1:
The electrode tab is bent at multiple angles (first bending part, second bending part, third bending part) to change its spatial configuration from a straight extension to a three-dimensional folded structure. This allows the battery pack to achieve larger capacity through optimized cell arrangement while maintaining compact overall dimensions by utilizing vertical and lateral space efficiently.
3Length of moving object
If electrode tab is bent to reduce battery pack size, then battery pack length is reduced, but structural complexity increases
Solution Approach 1:
The electrode tab structure is divided into distinct functional segments: the electrode sealing unit, the first bending part, the second bending part, and the third bending part. Each segment serves a specific purpose (sealing, spatial configuration, connection), which simplifies the manufacturing process and quality control despite the complex overall shape.
Solution Approach 2:
Instead of extending the electrode tab in a straight line to simplify construction, the design inverts the approach by folding the tab multiple times to create a compact three-dimensional structure. This inversion reduces the battery pack length while the segmentation principle keeps the manufacturing process manageable.
4Volume of moving object
If protection circuit module is integrated into battery cell structure, then battery pack size is reduced, but manufacturing complexity increases
Solution Approach 1:
The protection circuit module is merged with the battery cell structure by positioning the substrate within the space created by the bent electrode tab. The connection between the electrode tab and substrate tab integrates the protection circuit into the battery assembly process, allowing simultaneous installation rather than separate assembly steps.
Data Source
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AI summary
A battery pack (10) includes a battery cell (100), and a protection circuit module (200) connected to the battery cell (100), the battery cell (100) including an electrode assembly (110) and an electrode tab (120) extending from the electrode assembly (110), wherein the protection circuit module (200) includes a substrate (210) and a substrate tab (220) connected to the substrate (210), wherein the electrode tab includes an electrode sealing unit (1201) extending from a housing (140) of the electrode assembly and an electrode bending unit (1202) extending from the electrode sealing unit, wherein the electrode sealing unit is bendable between the substrate and the electrode assembly so that a first sealing surface (1201F1) of the electrode sealing unit faces a housing surface of the electrode assembly, and wherein a surface of the substrate faces a second sealing surface (1201F2) of the electrode sealing unit.