Battery Insulation Spacer Tab Alignment
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Solution Overview
Problem
Secondary batteries face challenges in maintaining insulation and alignment of electrode tabs, particularly under severe environments such as high-frequency vibrations or fall shock, due to inadequate positioning and welding of electrode tabs and insulation spacers.
Innovation Solution
Incorporating an insulation spacer with specific openings for electrode tabs to improve alignment and welding efficiency, and providing a robust insulating characteristic by interposing it between the electrode assembly and the cap plate, using materials like polypropylene or ethylene propylene diene monomer, which prevents electrical interference and ensures secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrode tabs are positioned without an insulation spacer, then the device complexity is reduced, but the alignment precision and positioning accuracy of electrode tabs deteriorate
Solution Approach 1:
An insulation spacer is introduced as an intermediary component between the electrode assembly and the cap plate. The spacer features openings that guide and position the electrode tabs, ensuring precise alignment during assembly. This mediator component resolves the alignment precision issue without requiring complex positioning mechanisms, as the spacer's geometry inherently provides the necessary guidance.
Solution Approach 2:
The insulation spacer is pre-formed with openings positioned at specific locations and angles. These openings are prepared in advance to receive the electrode tabs, enabling automatic alignment when the tabs are inserted. This preliminary preparation of the spacer structure eliminates the need for complex real-time positioning adjustments during assembly.
2Reliability
If electrode tabs are welded without proper insulation, then the welding process is simplified, but the reliability of electrical insulation deteriorates under severe environments
Solution Approach 1:
The insulation spacer serves as a mediator that provides electrical isolation between the electrode tabs and the cap plate. The spacer material (such as polypropylene or ethylene propylene diene monomer) inherently possesses excellent insulation properties, ensuring reliable electrical isolation even under severe vibration and shock conditions. This single component simultaneously provides both mechanical positioning and electrical insulation functions.
Solution Approach 2:
The insulation spacer is designed with localized openings only where electrode tabs need to pass through, while maintaining insulating material in all other regions. This local quality approach provides insulation precisely where needed (around the openings and in the bulk material) without adding unnecessary complexity to areas where electrical isolation is not required.
3Manufacturing precision
If multiple openings are provided in the insulation spacer for electrode tabs, then the positioning accuracy is improved, but the manufacturing complexity increases
Solution Approach 1:
The insulation spacer is manufactured with multiple openings pre-positioned at the exact locations and orientations required for the electrode tabs. This preliminary formation of openings during spacer fabrication eliminates the need for subsequent complex positioning operations. The openings are created as integral features of the spacer structure, ensuring precise positioning without adding manufacturing steps.
Solution Approach 2:
The insulation spacer is designed as a universal component that simultaneously performs multiple functions: providing electrical insulation, positioning multiple electrode tabs through its openings, and maintaining structural integrity. By consolidating these functions into a single multi-functional component, the design achieves high positioning accuracy without proportionally increasing manufacturing complexity.
Data Source
AI summary
A battery includes an electrode assembly; a positive electrode tab and a negative electrode tab both extending from the electrode assembly; an insulation spacer having openings through which the positive and negative electrode tabs extend, and a positive electrode lead and a negative electrode lead coupled to the respective positive and negative electrode tabs in the insulation spacer, wherein each opening has a first opening and a second opening, and wherein the first opening is at a lower region of the insulation spacer and the second opening is at a side region of the insulation spacer.