Segmented Resin Current Collector for Weldable Battery Tabs
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Solution Overview
Problem
Existing electrode current collectors with a resin layer interposed between metal layers face difficulties in securely fixing electrode tabs and electrode leads due to high resistance and challenges in welding, particularly in pouch-shaped secondary batteries.
Innovation Solution
The electrode current collector features a polymer resin layer with a reduced area, inclined surface, and specific thickness distribution, allowing easy fixation of electrode tabs and leads through welding by using a deposition method to form the second metal layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin layer is interposed between two metal layers in the current collector, then safety is improved by quickly cutting off current flow in case of short circuit, but welding of electrode tabs to electrode leads becomes difficult due to high resistance and the resin layer blocking contact
Solution Approach 1:
The current collector is divided into two distinct regions: a first region with a three-layer structure (metal-resin-metal) for safety in the active material area, and a second region without the resin layer for welding electrode tabs and leads. This segmentation allows each region to fulfill its specific function without compromise.
Solution Approach 2:
The resin layer is selectively positioned only in the first region where active material is applied, while the second region maintains direct metal-to-metal contact. This local differentiation in structure enables the current collector to provide both safety (where resin is present) and weldability (where resin is absent).
2Reliability
If the metal layer is made thin to reduce weight and improve safety response, then current cutoff speed is improved, but manufacturing complexity increases due to the need for precise three-layer alignment
Solution Approach 1:
The resin layer and second metal layer are formed on the first metal layer in advance, creating a pre-assembled current collector structure. This preliminary formation simplifies the overall manufacturing process by integrating multiple layers into a single unit before assembly, reducing the need for complex alignment operations during battery assembly.
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 solution enables secure fixation and easy energization of electrode tabs and leads, enhancing safety and manufacturing efficiency in secondary battery assemblies.
Implementation Method 1
a second metal layer (30) provided on one surface of the polymer resin layer (20)... using a deposition method to form the second metal layer
Data Source
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AI summary
Disclosed are an electrode current collector including a first metal layer, a polymer resin layer provided on one surface of the first metal layer, and a second metal layer provided on one surface of the polymer resin layer, wherein the area of the polymer resin layer is less than the area of the first metal layer and less than the area of the second metal layer, a method of manufacturing the same, and a secondary battery electrode assembly including the same.