Multi-Assembly Secondary Battery Layout for Crack-Free Welding
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Solution Overview
Problem
Existing secondary batteries face challenges in increasing capacity while maintaining high density, as wound or stacked electrode assemblies can lead to electrode plate cracks and decreased welding rates during manufacturing.
Innovation Solution
A secondary battery design featuring two or more electrode assemblies with multiple first and second electrode plates, separators, and current collecting plates, arranged to improve weldability and prevent cracks, using a cap assembly with terminal portions and a cap plate to accommodate the electrode assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of wound electrode times is increased to increase capacity, then the capacity of the secondary battery is improved, but cracks occur in the electrode plate at rounded portions
Solution Approach 1:
The battery is divided into multiple electrode assemblies, each containing a limited number of wound electrodes (1-5 times). This segmentation prevents excessive winding in single assemblies, eliminating crack formation at rounded portions while maintaining high overall capacity through parallel connection of multiple assemblies.
Solution Approach 2:
The patent transitions from increasing capacity through single-dimensional winding multiplication to a multi-dimensional approach using multiple electrode assemblies arranged in parallel. This dimensional expansion allows capacity scaling without the mechanical stress problems of excessive winding.
2Quantity of substance
If the number of stacked electrodes is increased to increase capacity, then the capacity of the secondary battery is improved, but the number of electrode tabs increases, decreasing welding rate during manufacturing
Solution Approach 1:
Multiple first electrode plates are electrically connected in parallel within each electrode assembly, consolidating multiple tabs into fewer connection points. This merging reduces the total number of welding operations required while maintaining high capacity through parallel electrode configuration.
Solution Approach 2:
The electrode assembly structure serves multiple functions simultaneously: it increases capacity through multiple electrodes while reducing manufacturing complexity through parallel electrical connections. This multi-functional design achieves both high capacity and high welding efficiency.
3Quantity of substance
If more electrode assemblies are added to increase capacity, then the capacity and density of the secondary battery are improved, but the device complexity increases
Solution Approach 1:
The battery is segmented into multiple electrode assemblies with standardized internal structures (1-5 wound electrodes each). This modular segmentation allows systematic capacity scaling while maintaining consistent, manageable complexity within each assembly unit.
Solution Approach 2:
Multiple electrode assemblies are nested within a single battery case, with each assembly containing its own stacked electrodes and separators. This nested structure organizes complexity hierarchically, allowing high capacity through multiple assemblies while maintaining structural order and manageability.
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 proposed design enhances the weldability of electrode assemblies, allowing for higher capacity and density secondary batteries without the limitations of crack formation and decreased manufacturing efficiency.
Implementation Method 1
The first current collecting plate and the second current collecting plate may be welded by laser welding.
Data Source
AI summary
A secondary battery including two or more electrode assemblies including two or more first electrode plates, two or more second electrode plates, and separators between the first electrode plates and the second electrode plates; a case accommodating the electrode assembly; two or more first current collecting plates electrically connected to the first electrode plate; two or more second current collecting plates electrically connected to the second electrode plate; and a cap assembly including a first terminal portion and a second terminal portion electrically connected to the first current collecting plates and the second current collecting plates, respectively, and a cap plate coupled to the case.Because two or more electrode assemblies and a current collecting plate electrically connected to each electrode assembly are provided, the weldability of the electrode assembly may be improved. Accordingly, a secondary battery having high capacity and high density may be provided.