Wound Electrode Assembly Layout for Lower Tab Overlap Resistance
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Solution Overview
Problem
Existing secondary battery designs face challenges in optimizing space utilization and reducing substrate tab overlap, leading to increased resistance and reduced capacity due to uniform substrate thickness and material coating distribution.
Innovation Solution
The electrode assembly features a first electrode with a first uncoated portion having a varying thickness and a first region thinner than the active material coated portion, accompanied by a first insulating layer and substrate tabs with controlled thickness and shape variations to minimize overlap and enhance space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform substrate thickness is used in the electrode assembly, then manufacturing is simplified, but space utilization is reduced and resistance increases due to substrate tab overlap
Solution Approach 1:
The substrate is designed with varying thickness across different regions: a first region with first thickness, a second region with second thickness greater than the first, and a third region with third thickness greater than the first. This local quality variation optimizes space utilization in different areas of the electrode assembly while managing substrate tab overlap effectively
2Ease of manufacture
If uniform substrate thickness is used in the electrode assembly, then manufacturing is simplified, but resistance increases due to substrate tab overlap
Solution Approach 1:
The substrate thickness is locally optimized with different thickness values in different regions. The first region has thickness suitable for low resistance, while the second and third regions have increased thickness to reduce overlap and improve structural integrity, thereby managing electrical resistance effectively
3Ease of manufacture
If uniform active material coating is applied, then manufacturing is simplified, but capacity is reduced due to suboptimal space utilization
Solution Approach 1:
The active material coating is applied with varying thickness across different regions of the substrate. The first active material layer corresponds to the first region with first thickness, the second active material layer corresponds to the second region with second thickness, and the third active material layer corresponds to the third region with third thickness. This local quality variation maximizes capacity by optimizing active material distribution in different areas
Data Source
AI summary
A secondary battery, including an electrode assembly having a first electrode, a second electrode, and a separator between the first electrode and the second electrode, wound around a winding axis, a case configured to accommodate the electrode assembly, the case electrically connected to the second electrode, and a cap assembly configured to seal an opening of the case, the cap assembly electrically connected to the first electrode, wherein the first electrode includes a first active material coated portion including a substrate in which an active material is coated along a winding direction and a first uncoated portion including a substrate in which an active material is not coated, and the first uncoated portion of the first electrode includes a first region having a thickness less than a thickness of the substrate of the first active material coated portion.