Secondary Battery Tab Layout for Complete Current Collector Welding
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Solution Overview
Problem
The conventional secondary battery manufacturing process is complicated and costly due to the need for two electrode tabs per polarity, leading to increased production and material costs, and the risk of welding omissions during the electrode tab-to-current collector welding process.
Innovation Solution
A secondary battery design where each electrode plate has a single electrode tab bent toward the central area, allowing for simplified welding of a current collector, reducing the number of welding processes and minimizing welding omissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two electrode tabs are formed on each polarity electrode plate, then welding omissions are prevented, but the welding process becomes complicated and production costs increase
Solution Approach 1:
The electrode plate is divided into two separate electrode plates, each with one electrode tab. This segmentation allows each tab to be welded independently to the current collector, ensuring complete welding coverage while simplifying the welding process compared to handling two tabs on a single plate.
Solution Approach 2:
The patent uses multiple electrode plates with identical single-tab configurations. Each electrode plate is a copy of the same design, ensuring consistent welding procedures and reducing process complexity through standardization across multiple units.
2Reliability
If two electrode tabs are formed on each polarity electrode plate, then welding omissions are prevented, but material costs and production costs increase
Solution Approach 1:
Instead of using one electrode plate with two tabs requiring more material, the patent segments into two smaller electrode plates each with one tab. This reduces material consumption per plate while maintaining welding completeness through the segmented approach.
Solution Approach 2:
The patent design allows for more efficient material utilization by creating electrode plates with single tabs that can be manufactured with optimized material usage, reducing waste compared to the conventional two-tab design.
3Ease of manufacture
If a single electrode tab is bent toward the central area, then the welding process is simplified, but the risk of welding omissions increases
Solution Approach 1:
The electrode assembly is segmented into multiple electrode plates, each with a single tab bent toward the central area. This segmentation maintains welding simplicity while ensuring completeness because each segmented unit has only one tab to weld, eliminating the complexity of welding multiple tabs on a single plate.
Solution Approach 2:
The electrode tabs are preliminarily bent toward the central area before the welding process. This preliminary positioning ensures that all tabs are correctly oriented and accessible for welding, preventing welding omissions while maintaining process simplicity.
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 approach simplifies the manufacturing process, reduces costs, and enhances process stability by ensuring all electrode tabs are properly welded, thereby improving the efficiency and reliability of the battery production.
Implementation Method 1
The welding process is referred to as laser plate welding (LPW)
Data Source
AI summary
A secondary battery includes: an electrode assembly including a plurality of electrode plates, each including an electrode tab bent toward a central area of the electrode assembly; a current collector welded to the bent electrode tabs; and a terminal electrically connected to the current collector.