Source: http://patents.com/us-9806370.html
Timestamp: 2018-08-17 04:06:12
Document Index: 359696513

Matched Legal Cases: ['Application No. 12', 'Application No. 201210291351', 'Application No. 201210291351', 'Application No. 2012', 'Application No. 201210291351', 'Application No. 201210291351', 'art 210', 'art 210', 'art 210', 'art 210', 'art 250', 'art 250', 'art 250', 'art 250', 'art 250', 'arts 271', 'art 271', 'art 271', 'art 271', 'arts 272', 'art 272', 'art 272', 'art 272', 'arts 281', 'art 281', 'art 281', 'art 281', 'art 281', 'arts 282', 'art 282', 'art 282', 'art 282', 'art 282']

US Patent # 9,806,370. Secondary battery having a planarizing member - Patents.com
United States Patent 9,806,370
Ahn October 31, 2017
Ahn; Chang-Bum (Yongin-si, KR)
Ahn; Chang-Bum
Family ID: 1000002922414
13/466,962
US 20130045405 A1 Feb 21, 2013
61525121 Aug 18, 2011
Current CPC Class: H01M 2/18 (20130101); H01M 10/0468 (20130101); H01M 2/1673 (20130101); H01M 10/0431 (20130101); H01M 10/4235 (20130101); H01M 10/049 (20130101)
Current International Class: H01M 4/64 (20060101); H01M 2/16 (20060101); H01M 10/42 (20060101); H01M 10/04 (20060101); H01M 4/00 (20060101); H01M 2/18 (20060101)
Field of Search: ;429/94,135,131
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S61-034857 Feb 1986 JP
2000-188115 Jul 2000 JP
10-20060059690 Jun 2006 KR
10-20070081547 Aug 2007 KR
10-20110007785 Jan 2011 KR
Machine Translation of Applicant Disclosed KR 10-20060059690. cited by examiner .
Extended European Search Report dated Dec. 3, 2013 for corresponding EP Application No. 12 167 997.1. cited by applicant .
Office Action issued on Aug. 5, 2015 for Chinese Patent Application No. 201210291351.3. cited by applicant .
Office Action issued on Mar. 24, 2016 for Chinese Patent Application No. 201210291351.3. cited by applicant .
Japanese Office Action received in corresponding Japanese Patent Application No. 2012-166804 issued on Jun. 13, 2016 in 4 pages. cited by applicant .
Office Action dated Sep. 26, 2016 for Chinese Patent Application No. 201210291351.3, 10 pages. cited by applicant .
Office Action dated Mar. 13, 2017 for Chinese Patent Application No. 201210291351.3. cited by applicant.
1. A secondary battery comprising: an electrode assembly comprising a first electrode plate and a second electrode plate that each have planar surfaces whereon first and second electrode active materials are formed on the planar surfaces of first and second electrode plates respectively, and first and second electrode tabs are formed, respectively, and comprising a separator having an outer end disposed between and overlapping with the first and second electrode plates, and the second electrode plate while overlapping with the first electrode plate and the second electrode plate wherein the an outer end of the separator defines a first step with and one of the first or second electrodes plate define a step, and a second step with the second electrode plate; and at least one a planarizing member disposed on a first end of the at least one of first and second ends of the electrode assembly to support the first end of the electrode assembly, that are opposite each other on the first and second electrode plates electrode assembly, wherein the planarizing member comprises a stepped form that is complementary with a stepped surface exposed on the at least one of the first and second ends between the two electrode plates comprising at least the first and second steps, wherein the at least one planarizing member has: an inner surface that receives the stepped surface exposed on the at least one of the first and second ends between the two electrode plates comprising at least the first and second steps, so as to cover and planarize the stepped surface, wherein the inner surface comprises accepting parts for accepting one or more stepped forms among stepped forms of edges of the first and second electrode active materials, the first and second electrode tabs, edges of the first and second electrode plates, and an edge of the separator, and an outer surface of the at least one planarizing member member opposite the inner surface that receives the stepped surface of the first and second ends that is substantially planar and extends over substantially the entire at least one of first and second ends between the two electrode plates wherein the substantially planar outer surface extends parallel to the planar surfaces of the at least one of the first and second electrode plates, wherein the at least one planarizing member extends beyond the first and second steps formed by the outer end of the separator and one of the first or and second electrodes plates, and wherein the planarizing member consists of an insulating resin-based material that is coated and cured on the first end of the electrode assembly.
The electrode assembly 100 may be formed in a manner that first and second electrode plates 110 and 120 on which an electrode active material is coated are separated while having a separator 150 interposed therebetween, an additional separator 150' is also added to insulate the first and second electrode plates 110, 120 and then the first and second electrode plates 110 and 120, and the separators 150 are rolled together in the shape of a jelly roll. For example, the electrode assembly 100 may be formed in the shape of the jelly roll in a manner that the first end S1 of the electrode assembly 100 is a start of the roll, and the second end S2 of the electrode assembly 100 is an end of the roll.
In the embodiment, an edge 110e of the first electrode plate 110, and an edge 150e of the separator 150 may be exposed between the first and second electrode tabs 113 and 123, and the edges 110e and 150e form the stepped surface with the first and second electrode tabs 113 and 123. The planarizing member 210 that is formed to cover both the first and second electrode tabs 113 and 123 covers the stepped surface between the first and second electrode tabs 113 and 123 by including the edges 110e and 150e of the first electrode plate 110 and the separator 150, so that the stepped surface is not externally exposed, and a planarized surface is provided via a surface of the planarizing member 210.
The separator 150 may end while forming the edge 150e between the first and second electrode tabs 113 and 123, and in this regard, since the length of the separator 150 is short enough to expose the second electrode tab 123 disposed below the separator 150, the first and second electrode tabs 113 and 123 may be covered by the planarizing member 210.
The planarizing member 210 may have the flat surface, and its inner surface may be leveled to be complementary with the stepped surface of the electrode assembly 100. For example, the planarizing member 210 may have a stepped form and may have accepting parts or openings 210a, 210b, 210c, and 210d that accept the first electrode tab 113, the edge 110e of the first electrode plate 110, the edge 150e of the separator 150, and the second electrode tab 123, respectively, in a disposed order along a longitudinal direction of the electrode assembly 100. That is, the inner surface of the planarizing member 210 may have the first electrode tab accepting part 210a, the first electrode plate edge accepting part 210b, the separator edge accepting part 210c, and the second electrode tab accepting part 210d.
The planarizing member 210 may improve stability with respect to burrs formed on edges of the first and second electrode plates 110 and 120, e.g., a burr formed on the edge 110e of the first electrode plate 110. The first and second electrode plates 110 and 120 may be individualized by cutting sequential sheets into the first and second electrode plates 110 and 120 via a roll-to-roll process, and the burrs due to the cutting may be formed on the edges of the first and second electrode plates 110 and 120. The planarizing member 210 may have a sufficient thickness so as to cover the edges of the first and second electrode plates 110 and 120, e.g., the burr on the edge 110e of the first electrode plate 110, or to exceed projection of the burrs, so that the planarizing member 210 may prevent contact between the burrs and other inner sheets (e.g., the first and second electrode plates 110 and 120, and the separator 150).
FIG. 5 is a diagram schematically illustrating a process of rolling an electrode assembly according to a comparative example. Referring to FIG. 5, electrode active materials 15 and 25 are formed on first and second electrode plates 10 and 20, and uncoated portions on which the electrode active materials 15 and 25 are not formed are formed on ends of the first and second electrode plates 10 and 20. Afterward, first and second electrode tabs 13 and 23 are formed on the uncoated portions of the first and second electrode plates 10 and 20. The first and second electrode plates 10 and 20 are rolled while having a separator (not shown) interposed therebetween. For example, the first and second electrode plates 10 and 20 may be rolled by using the ends whereon the first and second electrode tabs 13 and 23 are formed as a roll start. In an early stage of the roll operation, the first electrode plate 10 is solely turned once, and after the first electrode plate 10 is solely turned once so as to overlap on its uncoated portion 10a, the first electrode plate 10 may overlap with the second electrode plate 20 and then may be rolled together. For example, the first electrode plate 10 is turned once with respect to a dotted line of FIG. 5 so that the first electrode tab 13 overlaps on the uncoated portion 10a, and thus a step or a burr of the first electrode tab 13 is covered by the uncoated portion 10a. By doing so, inner damage in the electrode assembly may be prevented.
The uncoated portion 10a relatively further extends on the first electrode plate 10 so as to have a sufficient length to surround the first electrode tab 13 by being turned once. However, if the uncoated portion 10a on which the electrode active material 15 is not formed further extends, a length of the electrode active material 15 for generation of charges is decreased so that charging and discharging efficiency of the battery deteriorates.
The planarizing member 210 may extend to cover all of the first electrode tab 113, the edge 110e of the first electrode plate 110, the edge 150e of the separator 150, and the second electrode tab 123 that form the stepped surface. However, when required, the first electrode tab 113, the edge 110e of the first electrode plate 110, the edge 150e of the separator 150, and the second electrode tab 123 that form the stepped surface of the first end S1 may be individually covered by the planarizing member 210, or may form different combinations and then may be covered by the planarizing member 210. The planarizing member 210 may have a seamlessly extending shape or two or more separated members so as to cover a selected part or the entire stepped surface.
FIG. 9 is a diagram illustrating a secondary battery according to another embodiment of the present invention. Referring to FIG. 9, a planarizing member 250 that is formed to cover first and second electrode tabs 113 and 123 may extend to cover an edge 115e of a first electrode active material 115. The first electrode active material 115 forms a boundary with an uncoated portion, and a step corresponding to a thickness of the first electrode active material 115 is formed at the edge 115e of the first electrode active material 115. The planarizing member 250 is formed to accept and cover the edge 115e of the first electrode active material 115, so that, when an electrode assembly 100 is rolled, it is possible to prevent inner damage of the electrode assembly 100 which is caused by the fact that the electrode assembly 100 faces the stepped edge 115e of the first electrode active material 115.
In the embodiment of FIG. 9, the planarizing member 250 may cover the first and second electrode tabs 113 and 123 and may extend to a position that is away from the first electrode tab 113, so that the planarizing member 250 may cover the edge 115e of the first electrode active material 115. For example, the planarizing member 250 may cover the first and second electrode tabs 113 and 123, may cover a stepped surface between the first and second electrode tabs 113 and 123, and may cover an edge 110e of a first electrode plate 110 and an edge 150e of a separator 150 between the first and second electrode tabs 113 and 123. Also, the planarizing member 250 may extend to the position that is away from the first electrode tab 113 in a longitudinal direction of the electrode assembly 100, so that the planarizing member 250 may cover the edge 115e of the first electrode active material 115.
In more detail, the planarizing member 250 may have a relatively flat surface and its inner surface may be leveled to be complementary with a stepped surface of the electrode assembly 100. For example, the planarizing member 250 may have a stepped form and may have accepting parts or openings 250a, 250b, 250c, 250d, and 250e that accept the edge 115e of the first electrode active material 115, the first electrode tab 113, the edge 110e of the first electrode plate 110, the edge 150e of the separator 150, and the second electrode tab 123, respectively, in a disposed order along the longitudinal direction of the electrode assembly 100. That is, the inner surface of the planarizing member 250 may have the first electrode active material edge accepting part 250a, the first electrode tab accepting part 250b, the first electrode plate edge accepting part 250c, the separator edge accepting part 250d, and the second electrode tab accepting part 250e.
FIG. 11 is a perspective view of a secondary battery according to another embodiment of the present invention. FIG. 12 is a cross-sectional view of the secondary battery of FIG. 11. Referring to FIGS. 11 and 12, a first planarizing member 271 is formed on a first end S1 of an electrode assembly 100. The first planarizing member 271 may extend to cover all of a first electrode tab 113, an edge 110e of a first electrode plate 110, and an edge 150e of a separator 150 that form a stepped form. On the first end S1 of the electrode assembly 100, a length of the separator 150 may be greater than a length of the first electrode plate 110 and may be less than a length of a second electrode plate 120. However, in another embodiment, the separator 150 may extend further than the first and second electrode plates 110 and 120.
The first planarizing member 271 extends to cover all of the first electrode tab 113, the edge 110e of the first electrode plate 110, and the edge 150e of the separator 150, and accepts the stepped surface formed by them, so that the first planarizing member 271 may prevent an inner damage that is caused by facing another portion of the electrode assembly 100.
In more detail, the first planarizing member 271 may have a relatively flat surface, and its inner surface may be leveled to be complementary with a stepped surface of the electrode assembly 100. For example, the first planarizing member 271 may have a stepped form and may have accepting parts 271a, 271b, and 271c that accept the first electrode tab 113, the edge 110e of the first electrode plate 110, and the edge 150e of the separator 150, respectively, in a disposed order along a longitudinal direction of the electrode assembly 100. That is, the inner surface of the first planarizing member 271 may have the first electrode tab accepting part 271a, the first electrode plate edge accepting part 271b, and the separator edge accepting part 271c.
However, when required, the first electrode tab 113, the edge 110e of the first electrode plate 110, and the edge 150e of the separator 150 that form the stepped surface of the first end S1 may be individually covered by the first planarizing member 271, or may form different combinations and then may be covered by the first planarizing member 271. The first planarizing member 271 may have a seamlessly extending shape or two or more separated members so as to cover a selected part or the entire stepped surface.
A second planarizing member 272 may be formed on a second end S2 of the electrode assembly 100. The second planarizing member 272 may extend to cover all of a second electrode tab 123, an edge 150e of the separator 150, and an edge 110e of the first electrode plate 110 that form a stepped form. On the second end S2 of the electrode assembly 100, the length of the separator 150 may be greater than the length of the first electrode plate 110 and may be less than the length of the second electrode plate 120. However, in another embodiment, the separator 150 may extend further than the first and second electrode plates 110 and 120.
The second planarizing member 272 extends to cover all of the second electrode tab 123, the edge 150e of the separator 150, and the edge 110e of the first electrode plate 110, and accepts the stepped surface formed by them, so that the second planarizing member 272 may prevent an inner damage that is caused by facing another portion of the electrode assembly 100.
In more detail, the second planarizing member 272 may have a relatively flat surface, and its inner surface may be leveled to be complementary with a stepped surface of the electrode assembly 100. For example, the second planarizing member 272 may have a stepped form and may have accepting parts 272a, 272b, and 272c that accept the second electrode tab 123, the edge 150e of the separator 150, and the edge 110e of the first electrode plate 110, respectively, in a disposed order along the longitudinal direction of the electrode assembly 100. That is, the inner surface of the second planarizing member 272 may have the second electrode tab accepting part 272a, the separator edge accepting part 272b, and the first electrode plate edge accepting part 272c.
However, when required, the second electrode tab 123, the edge 150e of the separator 150, and the edge 110e of the first electrode plate 110 that form the stepped surface of the second end S2 may be individually covered by the second planarizing member 272, or may form different combinations and then may be covered by the second planarizing member 272. The second planarizing member 272 may have a seamlessly extending shape or two or more separated members so as to cover a selected part or the entire stepped surface.
For example, the first planarizing member 281 may extend to cover all of an edge 115e of a first electrode active material 115, a first electrode tab 113, an edge 110e of a first electrode plate 110, and an edge 150e of a separator 150 that form a stepped surface.
In more detail, the first planarizing member 281 may have a relatively flat surface and its inner surface may be leveled to be complementary with the stepped surface of the electrode assembly 100. For example, the first planarizing member 281 may have a stepped form and may have accepting parts 281a, 281b, 281c, and 281d that accept the edge 115e of the first electrode active material 115, the first electrode tab 113, the edge 110e of the first electrode plate 110, and the edge 150e of the separator 150, respectively, in a disposed order along the longitudinal direction of the electrode assembly 100. That is, the inner surface of the first planarizing member 281 may have the first electrode active material edge accepting part 281a, the first electrode tab accepting part 281b, the first electrode plate edge accepting part 281c, and the separator edge accepting part 281d.
However, when required, the edge 115e of the first electrode active material 115, the first electrode tab 113, the edge 110e of the first electrode plate 110, and the edge 150e of the separator 150 that form the stepped surface of the first end S1 may be individually covered by the first planarizing member 281, or may form different combinations and then may be covered by the first planarizing member 281. The first planarizing member 281 may have a seamlessly extending shape or two or more separated members so as to cover a selected part or the entire stepped surface.
For example, a second planarizing member 282 may extend to cover all of a second electrode tab 123, an edge 150e of the separator 150, an edge 110e of the first electrode plate 110, and an edge 115e of the first electrode active material 115 that form a stepped surface.
In more detail, the second planarizing member 282 may have a relatively flat surface and its inner surface may be leveled to be complementary with the stepped surface of the electrode assembly 100. For example, the second planarizing member 282 may have a stepped form and may have accepting parts 282a, 282b, 282c, and 282d that accept the second electrode tab 123, the edge 150e of the separator 150, the edge 110e of the first electrode plate 110, and the edge 115e of the first electrode active material 115, respectively, in a disposed order along the longitudinal direction of the electrode assembly 100. That is, the inner surface of the second planarizing member 282 may have the second electrode tab accepting part 282a, the separator edge accepting part 282b, the first electrode plate edge accepting part 282c, and the first electrode active material edge accepting part 282d.
However, when required, the second electrode tab 123, the edge 150e of the separator 150, the edge 110e of the first electrode plate 110, and the edge 115e of the first electrode active material 115 that form the stepped surface of the second end S2 may be individually covered by the second planarizing member 282, or may form different combinations and then may be covered by the second planarizing member 282. The second planarizing member 282 may have a seamlessly extending shape or two or more separated members so as to cover a selected part or the entire stepped surface.
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