Battery Cell Support Member to Prevent Tab Bifurcation
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Solution Overview
Problem
Existing battery cell designs face safety issues when inverted, as the gravity of the main body can cause bifurcation and insertion of the tab, leading to potential short circuits, fires, or explosions.
Innovation Solution
A battery cell design that includes a support member with a buckle portion, positioned between the end cover assembly and the main body, which supports the electrode assembly and prevents gravity-induced bifurcation and insertion of the tab, thereby enhancing safety and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery cell is inverted without support structure, then the structure is simple, but the tab is prone to bifurcation and insertion due to gravity, causing safety issues
Solution Approach 1:
A support member is introduced as an intermediary component between the electrode assembly and the end cover assembly. This support member includes a support body and a buckle portion that connects to the end cover assembly, providing structural support to prevent tab bifurcation and insertion when the battery cell is inverted, without requiring fundamental redesign of the overall battery structure
Solution Approach 2:
The support member is divided into distinct functional segments: a support body portion that directly supports the electrode assembly and prevents tab deformation, and a buckle portion that connects to the end cover assembly. This segmentation allows each part to perform its specific function efficiently while maintaining overall structural simplicity
2Reliability
If the buckle portion extends beyond the first or second surface, then the connection strength is high, but the volume occupation increases, reducing energy density
Solution Approach 1:
The buckle portion is designed with localized reinforcement only where needed for connection strength. The buckle portion is disposed between the first surface and the second surface of the support body, extending beyond only the first surface to connect with the end cover assembly, while maintaining a compact profile in other directions. This localized quality approach ensures adequate connection strength without unnecessary volume occupation
Solution Approach 2:
The buckle portion utilizes the thickness dimension of the support body effectively. By disposing the buckle portion between the first and second surfaces and extending beyond only the first surface, the design optimizes the use of available space in the thickness direction, minimizing volume occupation while maintaining connection functionality
3Strength
If the buckle portion extends beyond the first or second surface, then the connection is strong, but the support member is susceptible to fracture during production
Solution Approach 1:
The buckle portion is designed with localized reinforcement only where needed for connection strength, rather than uniformly thickening the entire support member. The buckle portion extends beyond only the first surface to provide adequate connection to the end cover assembly, while maintaining a compact profile that reduces susceptibility to fracture during handling and production processes
4Strength
If the buckle portion extends beyond the first or second surface, then the connection is strong, but material piling becomes unstable due to hooking between support members
Solution Approach 1:
The buckle portion is designed with localized extension beyond only the first surface, providing adequate connection strength while maintaining a compact overall profile. This localized approach prevents the support members from hooking onto each other during material piling operations, ensuring stable stacking and efficient production processes
Data Source
AI summary
A battery cell includes a shell, an electrode assembly, an end cover assembly, and a support member. The shell has an opening. The electrode assembly has a main body and a tab protruding from the main body, and the electrode assembly is accommodated in the shell. The end cover assembly closes the opening. The support member is located between the end cover assembly and the main body. The support member includes a support body and a buckle portion. The support body has first and second surfaces facing and facing away the end cover assembly, respectively, in a thickness direction of the end cover assembly. The buckle portion is disposed on the support body, in buckle fit with the end cover assembly, and located between the first and second surfaces. The support member is disposed between the end cover assembly and the main body of the battery cell.