Wound Electrode Assembly Layout for Low-Overlap Tab Welding
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Solution Overview
Problem
Existing electrode assemblies in secondary batteries experience inefficiencies in overlap areas 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 their bottom angles and widths change along the winding direction, minimizing segment overlap to less than 5%, ensuring efficient welding and improved flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segments are arranged with conventional overlapping in the winding direction, then manufacturing is simpler, but welding efficiency between segments and current collector decreases
Solution Approach 1:
The patent changes the segment arrangement from conventional overlapping in the winding direction to a non-overlapping configuration where segments are distributed along the radial direction. This dimensional shift eliminates the overlap issue while maintaining manufacturing simplicity, as segments are positioned at different radial levels rather than stacking in the same plane along the winding direction.
Solution Approach 2:
The current collector is divided into multiple segments that are spatially separated in the radial direction rather than overlapping in the winding direction. This segmentation approach allows each segment to be independently positioned and welded, improving welding efficiency while keeping the overall structure manageable through systematic distribution.
2Ease of manufacture
If segments overlap significantly in the winding direction, then segment formation is easier, but manufacturing precision and flatness deteriorate
Solution Approach 1:
The patent resolves the flatness issue by distributing segments along the radial direction instead of allowing them to overlap in the winding direction. This creates a stepped configuration where each segment occupies a different radial level, eliminating the flatness problems caused by overlapping while maintaining ease of segment formation through straightforward positioning.
3Quantity of substance
If segments are arranged with large overlap area, then material utilization is higher, but welding quality and reliability decrease
Solution Approach 1:
The patent segments the current collector into multiple radially-distributed sections, each forming a distinct welding interface with the electrode plate. This segmentation ensures that welding occurs at multiple separated locations rather than requiring high-quality welding across large overlapping areas, thereby improving welding quality and reliability while maintaining efficient material utilization through comprehensive electrode plate coverage.
Data Source
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.