Folded Double Electrode Tab Structure for Lamination Rigidity
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Solution Overview
Problem
The electrode tab in secondary batteries is prone to bending and damage during the lamination process, particularly when caught by rollers, due to reduced thickness and increased load, leading to potential defects in the battery.
Innovation Solution
The electrode tab is reinforced with a double structure comprising a first and second electrode tab, where the second tab is bent to overlap the first tab, and both are integrally bonded through welding, enhancing rigidity and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the collector of the electrode is reduced to increase battery capacity, then the battery capacity increases, but the electrode tab becomes thinner and more easily bent
Solution Approach 1:
The electrode tab structure transitions from a single-plane configuration to a multi-dimensional folded structure. The tab is folded back onto itself, creating overlapping layers that extend in multiple spatial dimensions. This dimensional transformation increases the moment of inertia and structural rigidity without adding material, thereby maintaining tab strength while using reduced-thickness collectors for higher battery capacity.
Solution Approach 2:
The electrode tab is designed with a nested structure where one portion of the tab is folded back and positioned within or alongside the main tab body. This nesting arrangement creates a compact, reinforced structure where the folded portion acts as an internal support element, increasing overall rigidity while minimizing material usage and maintaining a space-efficient design.
2Quantity of substance
If the electrode tab is reduced in thickness to increase battery capacity, then the battery capacity increases, but the electrode tab is easily caught by rollers and folded or damaged during lamination
Solution Approach 1:
The electrode tab is pre-folded or pre-shaped into its final reinforced configuration before the lamination process. This preliminary structuring ensures that the tab possesses adequate rigidity and resistance to deformation before it encounters rollers during manufacturing, preventing catching, folding, or damage while maintaining the space-efficient design needed for high battery capacity.
Solution Approach 2:
The electrode tab is divided into distinct functional segments: a main tab portion for electrical connection and a folded reinforcement portion for structural support. This segmentation allows the tab to perform multiple functions - maintaining electrical conductivity while providing mechanical strength to resist roller pressure and prevent damage during the lamination process.
3Ease of manufacture
If a single electrode tab structure is used, then the manufacturing process is simple, but the electrode tab lacks sufficient rigidity and is prone to bending
Solution Approach 1:
The electrode tab incorporates a dynamic folded structure that can adapt to manufacturing processes while providing enhanced rigidity. The fold creates a flexible yet strong configuration that can withstand handling and lamination forces, and the same structure can be implemented using standard manufacturing techniques without requiring complex additional processes or equipment.
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 reinforced electrode tab structure significantly reduces bending and damage, minimizing defects in the electrode assembly and secondary battery production.
Implementation Method 1
The first electrode tab and the second electrode tab are integrally bonded to each other through welding
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present invention relates to an electrode. The electrode comprises: a coating part coated with an electrode active material; and an electrode tab part provided on one side of the coating part, wherein the electrode tab part comprises: a first electrode tab connected to the one side of the coating part; and a second electrode tab connected to the first electrode tab and bent in a direction of the first electrode tab to overlap one surface of the first electrode tab.