Prismatic Battery Assembly With Bent Tabs for Lateral Insertion
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Solution Overview
Problem
The challenge of assembling a larger electrode assembly into a prismatic battery case is exacerbated by reduced empty space, making it difficult to insert and assemble the electrode assembly due to the limited lateral space in the case.
Innovation Solution
A secondary battery design with a laterally inserted electrode assembly and a manufacturing method that includes a case with an open lateral surface, a bent electrode tab, a terminal exposed outside the case, and an electrode plate insulating member to facilitate easy assembly and insulation, allowing for increased electrode assembly size within the limited space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the size of the electrode assembly is increased to increase battery capacity, then the energy storage capacity is improved, but it becomes difficult to insert the electrode assembly into the case due to reduction in empty space
Solution Approach 1:
The electrode tabs are bent before the electrode assembly is inserted into the case. This preliminary bending action allows the tabs to be positioned outside the case initially, providing sufficient empty space during insertion, and then the tabs are subsequently bent to their final positions after insertion, resolving the space constraint during assembly
Solution Approach 2:
The electrode assembly is segmented into the electrode plates and the electrode tabs. The tabs are separated from the main electrode plate body, allowing them to be bent and positioned independently. This segmentation enables the tabs to be manipulated outside the case during assembly while the main electrode assembly is inserted
2Quantity of substance
If the size of the electrode assembly is increased to increase battery capacity, then the energy storage capacity is improved, but the empty space in the case is reduced
Solution Approach 1:
The electrode tabs are extended into the lateral dimension outside the case rather than occupying vertical space within the case. By bending the tabs to extend laterally beyond the case opening, the design utilizes external space in a different dimension, preserving internal case volume for the electrode assembly
3Area of moving object
If the electrode tabs are made short to maximize electrode assembly area, then the electrode assembly size is improved, but the difficulty of welding and bending tabs increases
Solution Approach 1:
The welding and bending of electrode tabs are performed as preliminary actions before the electrode assembly is inserted into the case. This timing allows sufficient space and accessibility to perform these operations easily on longer tabs, and the bent tabs are then positioned outside the case during insertion
4Ease of manufacture
If the electrode assembly is laterally inserted into the case, then the assembly method is simplified, but the electrical insulation between electrode plate and terminal becomes more critical
Solution Approach 1:
An insulating member is introduced as an intermediary element between the electrode plate and the terminal. This insulating member prevents direct electrical contact and potential short circuits, ensuring reliable electrical insulation while allowing the lateral insertion assembly method to proceed
Data Source
Figure 1
Figure 2A
Figure 2B~3
AI summary
A secondary battery includes: a case having an open lateral surface; an electrode assembly inserted into the case through the open lateral side, the electrode assembly comprising a bent electrode tab; a terminal electrically connected to the bent electrode tab of the electrode assembly, the terminal being exposed to the outside of the case; a cover sealing the open lateral side of the case; and an electrode plate insulating member electrically insulating the electrode assembly from the terminal.