Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/543—Terminals
  • H01M50/547—Terminals characterised by the disposition of the terminals on the cells
  • H01M50/548—Terminals characterised by the disposition of the terminals on the cells on opposite sides of the cell
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/531—Electrode connections inside a battery casing
  • H01M50/536—Electrode connections inside a battery casing characterised by the method of fixing the leads to the electrodes, e.g. by welding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
  • B23K26/20—Bonding
  • B23K26/21—Bonding by welding
  • B23K26/24—Seam welding
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/04—Processes of manufacture in general
  • H01M4/0402—Methods of deposition of the material
  • H01M4/0404—Methods of deposition of the material by coating on electrode collectors
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
  • H01M4/139—Processes of manufacture
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/64—Carriers or collectors
  • H01M4/66—Selection of materials
  • H01M4/661—Metal or alloys, e.g. alloy coatings
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/10—Primary casings, jackets or wrappings of a single cell or a single battery
  • H01M50/116—Primary casings, jackets or wrappings of a single cell or a single battery characterised by the material
  • H01M50/117—Inorganic material
  • H01M50/119—Metals
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/10—Primary casings, jackets or wrappings of a single cell or a single battery
  • H01M50/116—Primary casings, jackets or wrappings of a single cell or a single battery characterised by the material
  • H01M50/121—Organic material
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/10—Primary casings, jackets or wrappings of a single cell or a single battery
  • H01M50/116—Primary casings, jackets or wrappings of a single cell or a single battery characterised by the material
  • H01M50/124—Primary casings, jackets or wrappings of a single cell or a single battery characterised by the material having a layered structure
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
  • H01M50/509—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the type of connection, e.g. mixed connections
  • H01M50/51—Connection only in series
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
  • H01M50/514—Methods for interconnecting adjacent batteries or cells
  • H01M50/516—Methods for interconnecting adjacent batteries or cells by welding, soldering or brazing
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/528—Fixed electrical connections, i.e. not intended for disconnection
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/531—Electrode connections inside a battery casing
  • H01M50/534—Electrode connections inside a battery casing characterised by the material of the leads or tabs
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/543—Terminals
  • H01M50/552—Terminals characterised by their shape
  • H01M50/553—Terminals adapted for prismatic, pouch or rectangular cells
  • H01M50/557—Plate-shaped terminals
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/543—Terminals
  • H01M50/562—Terminals characterised by the material
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/543—Terminals
  • H01M50/564—Terminals characterised by their manufacturing process
  • H01M50/566—Terminals characterised by their manufacturing process by welding, soldering or brazing
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/571—Methods or arrangements for affording protection against corrosion; Selection of materials therefor
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/50—Current conducting connections for cells or batteries
  • H01M50/572—Means for preventing undesired use or discharge
  • H01M50/584—Means for preventing undesired use or discharge for preventing incorrect connections inside or outside the batteries
  • H01M50/59—Means for preventing undesired use or discharge for preventing incorrect connections inside or outside the batteries characterised by the protection means
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2101/00—Articles made by soldering, welding or cutting
  • B23K2101/36—Electric or electronic devices
  • B23K2101/38—Conductors
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M2220/00—Batteries for particular applications
  • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M2220/00—Batteries for particular applications
  • H01M2220/30—Batteries in portable systems, e.g. mobile phone, laptop
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
  • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/60—Other road transportation technologies with climate change mitigation effect
  • Y02T10/70—Energy storage systems for electromobility, e.g. batteries

Definitions

• the present invention relates to an electrode plate for battery cells, and, more particularly, to an electrode plate device comprising a pair of electrode plates constructed in a structure in which the electrode plates include current collectors made of different materials (a, b), electrode taps are formed at the respective current collectors, and an electrode active material is applied to at least one major surface of each current collector excluding the electrode taps, wherein a metal piece made of the material (b) is welded to the end of the current collector made of the material (a) to form the electrode tap, and the electrode active material is applied to the current collector after the metal piece is welded to the current collector.
• the electrode plate device comprising a pair of electrode plates constructed in a structure in which the electrode plates include current collectors made of different materials (a, b), electrode taps are formed at the respective current collectors, and an electrode active material is applied to at least one major surface of each current collector excluding the electrode taps, wherein a metal piece made of the material (b) is welded to the end of the current collector made of the material (a)
• a secondary battery which can be charged and discharged, has been widely used as an energy source for wireless mobile devices. Also, the secondary battery has attracted considerable attention as a power source for electric vehicles (EV) and hybrid electric vehicles (HEV), which have been developed to solve problems, such as air pollution, caused by existing gasoline and diesel vehicles using fossil fuel.
• EV electric vehicles
• HEV hybrid electric vehicles
• Small-sized mobile devices use one or several battery cells for each device.
• middle- or large-sized devices such as vehicles, use a middle- or large- sized battery module having a plurality of battery cells electrically connected with each other because high output and large capacity are necessary for the middle- or large-sized devices.
• the middle- or large-sized battery module is manufactured with small size and small weight if possible.
• a prismatic battery or a pouch- shaped battery which can be stacked with high integration and has a small weight to capacity ratio, is usually used as a battery cell of the middle- or large-sized battery module.
• much interest is currently generated in the pouch-shaped battery, which uses an aluminum laminate sheet as a sheathing member, because the weight of the pouch-shaped battery is small and the manufacturing costs of the pouch-shaped battery are low.
• the pouch-shaped battery includes an electrode assembly constructed in a structure in which pluralities of cathodes and anodes are sequentially stacked while separators are disposed respectively between the cathodes and the anodes. From the cathodes and the anodes protrude pluralities of cathode taps and anode taps, which are coupled to a cathode lead and an anode lead, by welding, to form external input and output terminals.
• the cathodes are normally made of aluminum, whereas the anodes are normally made of copper.
• a cathode current collector, a cathode tap, and a cathode lead, which constitute each cathode are made of aluminum
• an anode current collector, an anode tap, and an anode lead, which constitute each anode are made of copper. Consequently, a large quantity of heat is not generated although the components constituting the cathodes and the anodes are coupled to each other by welding.
• battery cells are connected in series with each other in order to provide high output. Pouch-shaped battery cells are connected with each other through the coupling between the cathode lead, made of aluminum, and the anode lead, made of copper, to each other, which is accomplished by welding.
• Japanese Patent Application Publication No. 2004-247244 discloses a technology for constituting a battery cell by using a cathode lead made of copper and aluminum and an anode lead made of copper. Specifically, the copper is joined to the aluminum end of the cathode lead, and the joint region is wrapped by an electric insulation member, such that the cathode lead and the anode lead are made of the same material at the electrical connection region between the cathode lead and the anode lead, whereby the welding process is easily performed without the generation of heat.
• the joint region between the copper and aluminum part of the cathode lead is not formed by the welding but by applying resin while the copper and aluminum parts are in contact with each other, with the result that the coupling force between the copper and the aluminum at the joint region is small, and, in addition, the connection resistance is increased during the electrical conduction of the battery cell.
• the copper/aluminum joint region is located on the electrode lead, and therefore, there is a possibility that the copper/aluminum joint region is adjacent to the sealing region of the battery case. For this reason, it is required that the size of the sealing part of the battery case be increased.
• the space defined between the electrode assembly and the sealing part i.e., the space at the region where the electrode taps and the electrode leads are coupled to each other, is increased, with the result that the safety of the battery is deteriorated, and the size of the battery is increased.
• Japanese Patent Application Publication No. 2005-339931 discloses a technology for coating the protrusion of an anode lead protruding outside each battery cell, which includes a cathode lead, made of aluminum, in addition to the anode lead, made of copper, with aluminum, and forming through holes in the cathode lead and the anode lead, thereby accomplishing the coupling between battery cells without welding, and therefore, preventing the corrosion at the coupling region between the battery cells.
• the above-described technology requires an additional process, such as plating, in the course of coating the anode lead with aluminum.
• the manufacturing process is complicated, and therefore, the manufacturing costs of the battery cell are increased.
• the present invention has been made to solve the above problems, and other technical problems that have yet to be resolved.
• an electrode plate device comprising a pair of electrode plates constructed in a structure in which the electrode plates include current collectors made of different materials (a, b), electrode taps are formed at the respective current collectors, and an electrode active material is applied to at least one major surface of each current collector excluding the electrode taps, wherein a metal piece made of the material (b) is welded to the end of the current collector made of the material (a) to form the electrode tap, and the electrode active material is applied to the current collector after the metal piece is welded to the current collector.
• the cathode current collector and the anode current collector are made of different materials (a, b), whereas the electrode taps, protruding from the cathode current collector and the anode current collector, are made of the same material (b).
• cathode taps and anode taps, protruding from the battery cell are made of the same material, and therefore, it is possible to couple electrode leads, made of the same material as the cathode taps and the anode taps, to the cathode taps and the anode taps.
• the electrode leads, made of the same material are coupled to each other, whereby the weldability between the electrode taps and the electrode leads and between the respective electrode leads is improved.
• the coupling regions between the different materials are located on the electrode taps, and therefore, the size of the battery cell is not increased, and the sealability is not decreased at the sealing part of a battery case having the same size as a conventional battery cell.
• the material (a) is a material having a relatively high corrosion resistance
• the material (a) is located inside the battery cell, thereby improving the corrosion resistance in an atmosphere containing salt.
• the welding of the metal piece to the current collector is performed by laser seam welding or resistance welding.
• the laser seam welding or the resistance welding provides a high coupling force; however, a large quantity of heat is generated at the coupling region. Consequently, when the laser seam welding or the resistance welding is performed to the electrode taps protruding from the current collectors, to which the electrode active material is applied, the welding heat is transmitted to the current collectors, with the result that the electrode active material is deteriorated, and therefore, the coupling force is decreased.
• the welding process is normally performed using an ultrasonic welding method because the amount of welding heat is relatively small although the coupling force is low.
• the metal pieces are welded to the current collector to form the electrode taps, and then the electrode active material is applied to the current collector. Consequently, it is possible to use the laser seam welding or the resistance welding, which provides a high coupling force.
• the metal piece made of the material (b) may be directly welded to the current collector made of the material (a). Preferably, however, the metal piece made of the material (b) is welded to a small-sized welding part protruding from the current collector. The welding part of the current collector further facilitates the welding operation of the metal piece.
• one of the electrode plate pair i.e., the electrode plate made of the material (a)
• the other of the electrode plate pair i.e., the electrode plate made of the material (b)
• a current collector made of copper may be used as the anode plate.
• a metal piece made of copper is welded to the current collector made of aluminum to form an electrode tap (first electrode tap), and the current collector made of copper includes an electrode tap (second electrode tap) made of the same material as the current collector, i.e., copper, the electrode tap extending from the current collector.
• the first electrode tap and the second electrode tap have the same length.
• the current collector made of aluminum has a welding part protruding therefrom, the welding part having a length equivalent to 1/4 to 2/3 the length of the second electrode tap, and a metal piece made of copper is welded to the welding part of the current collector made of aluminum to form the first electrode tap having approximately the same size as the second electrode tap.
• a method of manufacturing the electrode plates constructed as described above including (i) welding a plurality of metal pieces, made of a material (b), to a long sheet-type current collector (A), made of a material (a), to form a plurality of electrode taps (first electrode taps), (ii) applying an electrode active material to at least one major surface of the current collector (A) excluding the regions where the first electrode taps are formed, (iii) applying an electrode active material to at least one major surface of a long sheet-type current collector (B), made of a material (b), excluding regions where a plurality of electrode taps (second electrode taps), made of the same material (b) as the current collector (B), which extend from the current collector (B), are formed, and (iv) cutting the two current collectors (A, B), to which the active material is applied, into a predetermined size including at least one of the electrode taps.
• the method includes welding a long metal strip, made of a material (b), to the long sheet-type current collector (A), made of the material (a), to form regions corresponding to the electrode taps (first electrode taps), instead of the step (i).
• the metal strip may be cut in the form of the first electrode taps at the step (iv).
• a battery cell including the electrode plates constructed as described above.
• the battery cell includes an electrode assembly constructed in a structure in which a plurality of electrode plates are sequentially stacked, and electrode leads, made of the same material as the electrode plates, are connected to ends of electrode taps protruding from the electrode plates.
• the electrode leads may be connected to the electrode taps in various manners.
• the electrode leads are connected to the electrode taps by ultrasonic welding. This is because it is possible to sufficiently obtain a desired coupling force using only the ultrasonic welding when the electrode taps and the electrode leads, which are made of the same material, are connected to each other. That is, it is possible to accomplish the electrical connection between the electrode taps and the electrode leads while the conduction of heat to the electrode active material, which is applied to the current collector, is minimized.
• the connection between the electrode taps and the electrode leads may be performed by the laser seam welding or the resistance welding as described above.
• the material of the electrode leads is not particularly restricted so long as the electrode leads are made of the same material as the electrode taps, to which the electrode leads are connected. That is, the electrode leads may be made of various materials. Specifically, the outer ends of the cathode taps and the anode taps of the battery cell according to the present invention are made of the same material, as described above, and therefore, the cathode leads and the anode leads, which are connected to the cathode taps and the anode taps, may also be made of the same material.
• the electrode leads are preferably made of copper.
• the battery cell according to the present invention is preferably used in a pouch-shaped battery having an electrode assembly mounted in a battery case made of a laminate sheet, preferably an aluminum laminate sheet, including a metal layer and a resin layer.
• insulative films are attached to the upper and lower surfaces of the electrode leads at the regions where the electrode leads are in contact with a battery case, whereby the insulation between the battery case and the electrode leads is accomplished.
• a middle- or large-sized battery module having a high output and large capacity, wherein the battery module includes a plurality of battery cells as unit cells.
• the battery cells are connected in series with each other, such that cathodes and anodes of the battery cells are directly coupled to each other, thereby accomplishing the high output of the battery module.
• the cathode leads and the anode leads are made of the same material, and therefore, it is possible to accomplish a desired electrical connection between the battery cells without using additional bus bars.
• FIG. 1 is an exploded perspective view illustrating a battery cell including a plurality of electrode plates according to a preferred embodiment of the present invention
• FIG. 2 is a front see-through view of the battery cell shown in FIG. 1 after the battery cell is assembled;
• FIGS. 3 to 5 are front views illustrating a process for manufacturing a cathode plate according to an exemplary method of the present invention
• FIGS. 6 to 8 are front views illustrating a process for manufacturing a cathode plate according to another exemplary method of the present invention.
• FIG. 9 is a perspective view illustrating a battery module manufactured by connecting two battery cells, one of which is shown in FIG. 1, to each other.
• FIG. 1 is an exploded perspective view illustrating a battery cell including a plurality of electrode plates according to a preferred embodiment of the present invention. For convenience of description, some electrode taps are omitted from the drawing.
• the battery cell 600 includes an electrode assembly 400, which is constructed in a structure in which a plurality of cathode plates 100, 101, 102 ... and a plurality of anode plates 200, 201, 202 ... are sequentially stacked, while separators 300 are disposed respectively between the cathode plates 100, 101, 102 ... and the anode plates 200, 201, 202 ..., mounted in a battery case 500.
• the cathode plate 100 has a cathode active material 120 applied to a cathode current collector 110.
• Cathode taps 130 protrude from opposite ends of the cathode plate 100.
• Each cathode tap 130 is constructed in a structure in which a metal piece made of copper (hereinafter, a copper piece 150) is welded to a small-sized welding part 140 protruding from the cathode current collector 110, made of aluminum.
• the anode plate 200 has an anode active material 220 applied to an anode current collector 210.
• Anode taps 230 protrude from opposite ends of the anode plate 200.
• FIG. 2 is a front see-through view typically illustrating the battery cell of FIG. 1 after the battery cell is assembled.
• the battery cell 600 is constructed in a structure in which the cathode lead 410 and the anode lead 420 protrude outside the battery case 500 at opposite ends of the battery case 500.
• the cathode lead 410 and the anode lead 420 are made of copper.
• the cathode lead 410 and the anode lead 420 are connected to the copper pieces 150 of the cathode taps 130 and the anode taps 230, respectively.
• Additional insulative films 430 are applied to the cathode lead 410 and the anode lead 420 at a sealing region 210 of the battery case 500.
• FIGS. 3 to 5 are front views typically illustrating a process for manufacturing the cathode plate according to an exemplary method of the present invention.
• a plurality of copper pieces 150, 151, 152 ... are fixed to predetermined regions of a long sheet-type aluminum current collector HOa by welding, a cathode active material 120 is applied to the current collector 110a, and the current collector HOa is cut, as shown in FIG. 5, to manufacture a cathode plate 110.
• the cathode plate 110 may have a cathode tap 130, which is constituted by the welding part 140 between the copper piece 150 and the aluminum current collector 110a, by cutting opposite side parts of the regions of the current collector 110a where the copper pieces 150, 151, 152 ... are fixed in a chamfer structure A.
• FIGS. 6 to 8 are front views typically illustrating a process for manufacturing a cathode plate according to another exemplary method of the present invention.
• the manufacturing method shown in these drawings is identical to the manufacturing method shown in FIGS. 3 and 4 except that a long copper strip 160 is fixed to the aluminum current collector 110a by welding, and then the copper strip 160 is cut.
• FIG. 9 is a perspective view typically illustrating a battery module manufactured by connecting two battery cells, one of which is shown in FIG. 1 , to each other.
• the battery module 700 includes two battery cells (a first battery cell 100 and a second battery cell 101) having cathode leads 410 and 412 and anode leads 420 and 422, all of which are made of copper, protruding from opposite ends of the battery cells 100 and 101, respectively.
• the two battery cells 100 and 101 are connected in series with each other through the coupling between the cathode lead 410 of the first battery cell 100 and the anode lead 422 of the second battery cell 101.
• the coupling between the cathode lead 410 and the anode lead 422 is easily accomplished by welding because both the cathode lead 410 and the anode lead 422 are made of copper.
• Two rectangular copper sheets having a length of 5 cm, a width of 1 cm, and a thickness of 500 ⁇ m, were placed on an ultrasonic welding machine such that ends of the copper sheets overlapped with each other by approximately 1 cm in the longitudinal direction of the copper sheets, a welding head was brought into contact with the overlapping region between the copper sheets, and ultrasonic energy having a frequency of approximately 40 KHz was applied to the overlapping region between the copper sheets. In this way, the ultrasonic welding was performed.
• Two metal sheets were fixed to each other by ultrasonic welding according to the same method as Example 1 except that a rectangular copper sheet, having a length of 5 cm, a width of 1 cm, and a thickness of 500 ⁇ m, and a rectangular aluminum sheet, having the same size as the rectangular copper sheet, were used.
• the welding strength of the metal sheets welded according to Example 1 and Comparative example 1 were measured by an ASTM test method.
• a long copper strip was connected to a predetermined region of a long sheet-type aluminum foil by laser seam welding, and a cathode mixture slurry, prepared by adding 95 weight percent of LiCoO 2 , 2.5 weight percent of Super-P (a conducting agent), and 2.5 weight percent of PVdf (a binder) to N- methyl-2-pyrrolidone (NMP) as a solvent, was applied to opposite major surfaces of the aluminum foil. Subsequently, the aluminum foil was cut, as shown in FIG. 8, to manufacture a cathode plate having a cathode tap formed at one side thereof.
• a cathode mixture slurry prepared by adding 95 weight percent of LiCoO 2 , 2.5 weight percent of Super-P (a conducting agent), and 2.5 weight percent of PVdf (a binder) to N- methyl-2-pyrrolidone (NMP) as a solvent, was applied to opposite major surfaces of the aluminum foil. Subsequently, the aluminum foil was cut, as shown in FIG. 8, to manufacture a
• An anode mixture slurry prepared by adding 95 weight percent of artificial graphite, 2.5 weight percent of Super-P (a conducting agent), and 2.5 weight percent of PVdf (a binder) to NMP as a solvent, was applied to opposite major surfaces of a long sheet-type copper foil. Subsequently, the copper foil was cut in the chamfer structure shown in FIG. 8 to manufacture an anode plate having an anode tap formed at one side thereof.
• This electrode assembly was mounted in a battery case, and an electrolyte is injected into the electrode assembly. In this way, a battery cell was manufactured.
• a battery module was manufactured according to the same method as Example 2 except that each cathode plate was provided at one end thereof with a cathode tap made of aluminum, and each cathode lead was made of aluminum.
• the connection regions between the electrode leads were pulled to measure the tensile force at the connection regions until the connection regions broke.
• a battery cell was manufactured according to the methods described in Paragraph 2-1 to Paragraph 2-3 of Example 2 except that an electrode active material was applied to opposite major surfaces of the cathode current collector, copper taps were connected to the cathode current collector, at the region where the electrode active material was not applied, by laser seam welding, and then the cathode current collector was cut.
• a battery module was manufactured according to the same method as Example 2 except that the coupling between the electrode leads was performed by laser seam welding when the battery cells were connected in series with each other.
• Example 2 and Comparative example 3 were tested in a 1 OC-rate pulse cycle condition.
• the test results revealed that the battery cell manufactured according to Comparative example 3 exhibited faster capacity reduction, during a charge and discharge cycle, than the battery cell manufactured according to Example 2.
• the capacity of the battery cell manufactured according to Comparative example 3 was reduced by approximately 20 % at 100 cycles as compared to that of the battery cell manufactured according to Example 2.
• the capacity of the battery cell manufactured according to Comparative example 3 was reduced by approximately 28 % at 200 cycles as compared to that of the battery cell manufactured according to Example 2. This is because some of the active material was deteriorated due to the conductive heat when the laser seam welding was performed to the cathode current collector having the active material applied thereto.
• the cycle characteristics of the battery modules manufactured according to Example 2 and Comparative example 4 were tested in a IOC-rate pulse cycle condition.
• the test results revealed that the output of the battery module manufactured according to Comparative example 4 was reduced by approximately 34 % at 200 cycles as compared to that of the battery module manufactured according to Example 2.
• the capacity of the battery module manufactured according to Comparative example 4 was reduced by approximately 26 % at 200 cycles as compared to that of the battery module manufactured according to Example 2. This is because some of the active material was deteriorated by high-temperature heat generated when the laser seam welding was performed to interconnect the electrode leads, whereby the capacity and output of the battery module manufactured according to Comparative example 4 were considerably reduced in a high output condition.
• the connection between the electrode leads was performed by ultrasonic welding, which generated a relatively small amount of heat, whereby the battery module manufactured according to Example 2 exhibited a high output and capacity maintenance ratio even in a high-output charge and discharge condition.
• the electrode plate according to the present invention has the effect of improving the weldability between the cathode terminal and the anode terminal when two battery cells, which include the electrode plate, are connected in series with each other to manufacture a battery module.
• the electrode plate according to the present invention has the effect of improving the corrosion resistance in an atmosphere containing salt.

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• 2007
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