Acute-Angle Tab Plate Geometry for Low-Pressure Wound Batteries
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Solution Overview
Problem
The manufacturing process of full-tab wound batteries often results in the active materials on electrode plates being dislodged and deformed due to the high pressure required to flatten the tabs, leading to reduced performance and yield.
Innovation Solution
A tab plate design with an acute angle between the tab sides and the partition line reduces the rolling pressure needed for flattening, preventing material loss and deformation, and separates the cutting area from the coating area to prevent active material powder from falling off during tab formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If significant pressure is applied to flatten the tabs during winding, then the tabs can be flattened, but the active materials on the electrode plates fall off and the electrode plates deform
Solution Approach 1:
The patent changes the geometric parameters of the tab, specifically setting the angle between the first side and the partition line to be an acute angle (specifically 45 degrees). This parameter change allows the tab to be flattened with significantly reduced rolling pressure during winding, preventing active material loss while achieving the required flatness
Solution Approach 2:
The patent introduces asymmetric design by making the angle between the first side and partition line different from the angle between the second side and partition line. The first angle is set to 45 degrees (acute) while the second angle is not specified to be acute, creating an asymmetric tab structure that optimizes flattening behavior
2Shape
If significant pressure is applied to flatten the tabs during winding, then the tabs can be flattened, but the electrode plates deform
Solution Approach 1:
By changing the tab geometry parameters (setting the first angle to 45 degrees acute angle), the patent enables tab flattening with minimal pressure, thereby preventing electrode plate deformation while achieving the required tab flatness
3Device complexity
If the cutting area is close to the coating area, then the tab formation is simpler, but cutting may reach the coating area and cause active material powder to fall off
Solution Approach 1:
The patent segments the empty foil area into two distinct regions: a cutting area and a reserved area. The reserved area acts as a buffer zone separating the cutting area from the coating area, ensuring that cutting operations do not reach the coating area and cause active material loss
Solution Approach 2:
The reserved area serves as an intermediary zone between the cutting area and the coating area. This intermediate region prevents direct contact between the cutting process and the coating area, thereby protecting the active material from being dislodged during tab formation
Data Source
AI summary
The present application provides a tab plate, including a coating area and an empty foil area located on one side of the coating area. The empty foil area includes a cutting area and a reserved area; the cutting area forms a plurality of tabs by cutting; the ends of the plurality of tabs close to the coating area are connected together through the reserved area; a partition line is formed at the connection position between the cutting area and the reserved area; each tab includes a first side and a second side which are opposite to each other, and both the first side and the second side intersect with the partition line; an angle a is formed between the first side and the partition line, the angle a is located within the tab, and the angle a is an acute angle.