Pouch Cell Tab-Lead Bonding for Stable Battery Connections
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Solution Overview
Problem
Existing secondary batteries face challenges in maintaining stable connections between electrode tabs and leads, leading to potential failure and reduced durability, especially in high-capacity applications.
Innovation Solution
A secondary battery design featuring an electrode assembly with a U-shaped and L-shaped bent electrode tab, connected via an adhesive film interposed between the electrode tab and lead, which is sealed within a pouch case, using materials like polypropylene for the adhesive film and ensuring the electrode lead is partially outside the case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adhesive film is attached to the connection portion between the electrode tab and the electrode lead, then the stability and durability of the electrode connection is improved, but the device complexity increases
Solution Approach 1:
An adhesive film is introduced as an intermediary component between the electrode tab and the electrode lead. This adhesive film serves as a mediator that enhances the bonding strength and electrical conductivity at the connection interface, thereby improving connection stability and durability without requiring complex alternative connection methods
Solution Approach 2:
The adhesive film is constructed using composite materials that combine adhesive properties with electrical conductivity. This composite structure allows the film to simultaneously provide mechanical bonding strength and maintain electrical continuity between the electrode tab and lead, improving reliability while keeping the added complexity minimal
2Reliability
If the electrode tab is bent into U shape and L shape inside the pouch case, then the connection stability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The electrode tab is pre-bent into U shape and L shape configurations before final assembly into the pouch case. This preliminary shaping allows the tab to be positioned and secured more easily during assembly, improving connection stability while reducing the precision requirements during the final manufacturing process
Solution Approach 2:
The electrode tab is formed with curved geometries (U shape and L shape) instead of straight configurations. These curved shapes provide mechanical flexibility and stress distribution, enhancing the durability and stability of the connection between the electrode and lead while accommodating variations in manufacturing tolerances
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 design enhances the stability and durability of the electrode connection, reducing failure rates and maintaining electrical integrity, particularly in high-capacity batteries used in vehicles and power storage systems.
Implementation Method 1
an adhesive film is attached to a connection portion between the electrode tab and the electrode lead
Data Source
AI summary
A secondary battery includes an electrode assembly including a first electrode, a separator, and a second electrode stacked therein, an electrode tab protruding from one side of the electrode assembly, an electrode lead connected to the electrode tab, and a pouch case accommodating the electrode assembly, the pouch case including a first cover and a second cover, wherein an adhesive film is attached to a connection portion between the electrode tab and the electrode lead, and the adhesive film is interposed between the first cover and the second cover.