Wound Electrode Assembly Layout for Low-Overlap Tab Segments
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Solution Overview
Problem
Existing electrode assemblies in secondary batteries experience significant overlap between adjacent segments, leading to reduced welding efficiency and manufacturing challenges.
Innovation Solution
The electrode assembly design includes a first and second electrode plate with uncoated portions forming segments that are arranged such that the bottom angle changes in the winding direction, minimizing segment overlap to less than 5% and optimizing the arrangement of segments using mathematical formulas to ensure efficient welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segments are arranged with uniform spacing in the winding direction, then manufacturing is simplified, but overlap area between adjacent segments increases significantly
Solution Approach 1:
The patent applies local quality by making the spacing between segments non-uniform in the winding direction. Specifically, the distance between adjacent segments varies along the winding path, with larger gaps positioned where segments would otherwise overlap significantly. This localized adjustment of spacing optimizes the overlap area without requiring complete redesign of the entire segment arrangement system.
2Manufacturing precision
If segment overlap area is reduced to improve welding efficiency, then welding quality improves, but segment arrangement complexity increases
Solution Approach 1:
The patent employs parameter changes by systematically varying the spacing parameters between segments along the winding direction. By adjusting the distance parameter between adjacent segments at different positions, the overlap area is controlled to be within acceptable limits (e.g., overlap ratio ≤ 5%). This parameter optimization achieves improved welding efficiency while maintaining a relatively simple segment arrangement that can be implemented through standard manufacturing processes.
Data Source
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AI summary
An electrode assembly, and a battery cell and a power source including the same are provided. The electrode assembly includes a first electrode plate wound about a winding axis and including a first uncoated portion without a first electrode active material coated thereon, a second electrode plate wound about the winding axis and including a second uncoated portion without a second electrode active material coated thereon, a separator disposed between the first electrode plate and the second electrode plate, and a plurality of segments formed on at least one of the first uncoated portion or the second uncoated portion. The plurality of segments are arranged such that at least one bottom angle is changed in a winding direction.