Battery Insulating Layers Prevent Tab Piercing
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Solution Overview
Problem
Batteries are prone to safety issues due to the risk of the packaging film being pierced or broken upon impact, which can lead to electrical short circuits and reduced reliability.
Innovation Solution
The battery design incorporates insulating layers with protective portions that cover the connecting regions of the tabs, preventing direct contact with the packaging film and acting as a buffer against impacts, thereby enhancing safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery uses a simple packaging film structure, then the manufacturing cost is low, but the packaging film is easily pierced by tabs during impact
Solution Approach 1:
The patent introduces insulating layers as intermediary components between the tabs and the packaging film. These insulating layers include protective portions that cover the tabs and packaging portions that cover the packaging film, preventing direct contact between the tab and the packaging film. This intermediary structure protects the packaging film from being pierced during impact while maintaining overall structural integrity.
Solution Approach 2:
The insulating layers are pre-installed on the tabs before battery assembly, providing protective cushioning in advance. The protective portions of the insulating layers extend beyond the tab surfaces, creating a buffer zone that absorbs impact forces before they can reach the packaging film, thereby preventing piercing during subsequent impact events.
2Reliability
If the battery uses thicker packaging film, then the impact resistance is improved, but the manufacturing cost increases
Solution Approach 1:
Instead of using thicker packaging film, the patent employs insulating layers as intermediary protective components. These insulating layers are made from cost-effective materials and can be applied through standard manufacturing processes, providing equivalent or superior impact protection compared to simply thickening the packaging film, thereby controlling manufacturing costs.
Solution Approach 2:
The patent uses composite material structures where insulating layers with specific protective properties are combined with the packaging film. This composite approach allows the packaging film to maintain its original thickness and cost-effectiveness while the insulating layers provide the necessary impact resistance and piercing protection.
3Reliability
If the insulating layer area is larger than the tab area, then the protection effect is improved, but the material usage increases
Solution Approach 1:
The insulating layers are designed with local quality differentiation. The protective portions have larger areas that extend beyond the tabs to provide comprehensive protection, while the packaging portions are precisely sized to cover only the necessary areas of the packaging film. This localized design ensures protection is concentrated where most needed without excessive material usage in non-critical areas.
Solution Approach 2:
The insulating layers are designed to extend beyond the minimum tab coverage area. This excessive action ensures that even during tab movement or deformation under impact, the protective coverage is maintained. The extended protective portions provide a safety margin that guarantees piercing protection while the material usage remains controlled through efficient design.
Data Source
AI summary
An impact-proofed battery includes a packaging film, an electrode assembly received in the packaging film, tabs extending from an end portion of the electrode assembly, and insulating layers. Each tab includes a connecting region, a packaging region, and an exposed region connected in the order written. The connecting region is electrically connected to the electrode assembly, and the exposed region is exposed from the packaging film. Each insulating layer includes a packaging portion and a protective portion connecting to the packaging portion. The packaging portion covers the packaging region and is between the packaging film and the packaging region. The protective portion is between the connecting region and the packaging film, and an area of the protective portion is greater than an area of the connecting region. The disclosure also provides a device using the battery.