Battery Cell Tab-Lead Bonding Layout for Smaller Terrace Area

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Solution Overview

Problem

Existing battery cells have inefficiencies in space utilization for electrode tabs, which limits energy density due to the space required for electrode connections.

Innovation Solution

The battery cell design includes an electrode assembly with an electrode tab and lead where the bonding portion is oriented to minimize space, using a protective member made of insulating material to cover and secure the connection, and a case that accommodates the assembly and protective member, allowing the lead to extend externally while reducing the terrace size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electrode tab is connected to the electrode lead by welding in a conventional pouch-type battery cell, then the electrical connection is reliable, but the space required for the electrode tab disposal increases, reducing energy density

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidterrace area for electrode tab

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The bonding portion is repositioned from the conventional in-plane arrangement to a configuration where it opposes the electrode assembly in the thickness direction. This dimensional change allows the electrode tab and electrode lead to be oriented in the same direction, minimizing the terrace area required while maintaining reliable bonding connection.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The electrode lead is designed with flexible positioning capability, allowing it to be oriented in the same direction as the electrode tab in the bonding portion. This dynamic orientation reduces the space required for electrode tab disposal while ensuring reliable electrical connection.

Inventive Principle:

Principle #15Dynamics

2Area of stationary object

If the bonding portion is minimized to increase energy density, then the space utilization improves, but the bonding portion becomes more susceptible to damage

Engineering Contradiction:

Improveterrace area for electrode tabVSAvoidbonding portion protection

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

A protective member is introduced as an intermediary element between the bonding portion and the external environment. This protective member covers the bonding portion, shielding it from damage while allowing the bonding portion to maintain its minimized configuration for improved space utilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective member is installed in advance to cover and protect the bonding portion before any potential damage can occur. This preemptive protection ensures the bonding portion remains intact while maintaining the minimized terrace area configuration.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20230369729A1Battery cell and method of manufacturing the same

Publication Date: 2023.11.16 SK ON CO LTD

AI summary

A battery cell includes an electrode assembly, an electrode tab drawn out from one surface of the electrode assembly, and an electrode lead to which the electrode tab is coupled, wherein a bonding portion in which the electrode tab and the electrode lead are bonded to each other is disposed to face the electrode assembly, and wherein, in the bonding portion, an end of the electrode tab and an end of the electrode lead are disposed to be oriented in the same direction.