Stacked Electrode Tab Bundle Structure for Compact Battery Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional secondary batteries face challenges in improving volumetric energy density due to unnecessary space for bonding of uncoated electrode portions and potential deformation issues that affect reliable electrical connections with current collector plates.
Innovation Solution
The electrode assembly features a bonding structure where electrode tabs of the same polarity are gathered at the center and bent outward, with sub-tabs bonded using laser welding to form a compact bundle, enhancing electrical connection and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding methods are used between uncoated portion and current collector plate, then electrical connection is achieved, but unnecessary space is consumed and volumetric energy density is reduced
Solution Approach 1:
The patent extracts the bonding function from the conventional large-space bonding structure and relocates it to the electrode tab tip, which protrudes through the separator. This eliminates the need for separate bonding space between the uncoated portion and current collector plate, as the electrode tab itself serves as the bonding interface.
Solution Approach 2:
The patent transitions from a planar bonding interface (uncoated portion bonded to current collector plate in the same plane) to a three-dimensional configuration where the electrode tab protrudes through the separator and bonds to the current collector plate from the opposite side, utilizing the thickness dimension of the separator.
2Ease of manufacture
If conventional bonding structure is used, then electrical connection is established, but deformation occurs leading to unreliable connection
Solution Approach 1:
The electrode tab is pre-formed with a protruding structure that extends through the separator before final assembly. This preliminary configuration ensures proper alignment and positioning, preventing deformation during the bonding process and subsequent operation.
Solution Approach 2:
The patent changes the geometric parameters of the electrode tab by extending it to protrude through the separator, transforming it from a flat in-plane structure to a three-dimensional protruding structure. This parameter change enhances mechanical stability and ensures reliable electrical connection.
3Volume of stationary object
If electrode tabs are gathered at center to form bundle, then bonding space is reduced and energy density improved, but bonding reliability must be maintained
Solution Approach 1:
Multiple electrode tabs of the same polarity are merged into a single bundled structure that protrudes through the separator. This consolidation reduces the total bonding space required while maintaining electrical connection reliability through the unified tab bundle configuration.
Solution Approach 2:
The electrode tabs are selectively gathered and bundled at specific locations (positive and negative poles) while maintaining their individual functionality. This localized bundling approach optimizes space utilization without compromising the electrical connection quality at each pole.
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 configuration improves energy density and structural stability by ensuring reliable electrical connections and reducing deformation, while allowing for efficient current collection and compact manufacturing.
Implementation Method 1
the sub-tab may be bonded to each side of the electrode tab bundle by laser welding
Data Source
AI summary
The present disclosure relates to an electrode assembly in which a plurality of first electrode plates including electrode tabs, a plurality of second electrode plates including electrode tabs, and a separator interposed between each of the first electrode plates and each of the second electrode plates are arranged in a stacked manner. In the electrode assembly, electrode tabs of the same polarity are bend-formed so that the electrode tabs are gathered at the center of the stacking direction of the electrode assembly and protrude outward, and sub-tabs may be bonded on the bend-formed electrode tabs. In addition, the present disclosure may include a manufacturing method of an electrode assembly in which a pair of sub-tabs is respectively bonded on opposite sides of a bundle of electrode tabs that are gathered at the center of the stacking direction of the electrode assembly and protrude outward as described above.