Battery Cell Insulation Spacer Channel for Tab Short-Circuit Isolation
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Solution Overview
Problem
Existing battery cells have a simple insulation spacer structure that increases the risk of short circuits due to tab contact with the housing, compromising safety performance and requiring tab adhesives, which complicates the internal structure and increases material and processing costs.
Innovation Solution
An insulation spacer with a first and second wall face, featuring a first and second opening and a channel that allows the tab to pass through and bend, reducing the risk of short circuits and eliminating the need for tab adhesives by providing a secure and efficient assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple insulation spacer structure is used, then the manufacturing cost is reduced, but the safety performance deteriorates due to tab contact with housing causing short circuits
Solution Approach 1:
The insulation spacer is divided into multiple functional regions: a first region with a first opening for tab insertion, a second region with a second opening for tab exit, and a third region forming a channel between them. This segmentation allows the tab to pass through the insulation spacer in a controlled manner, preventing contact with the housing while maintaining structural simplicity and manufacturability.
2Reliability
If a complex insulation spacer structure is used to prevent short circuits, then the safety performance is improved, but the device complexity increases
Solution Approach 1:
The insulation spacer integrates multiple functions into a single component: it provides electrical insulation, guides the tab through its thickness, supports the tab at multiple points (first opening, second opening, and channel), and prevents tab contact with the housing. This merging eliminates the need for separate adhesive layers and additional insulating components, reducing overall device complexity while maintaining high safety performance.
3Stability of the object's composition
If tab adhesive is used to secure the tab, then the assembly is stabilized, but the material cost and processing cost increase
Solution Approach 1:
The insulation spacer's channel structure with specific dimensions (width and height greater than the tab thickness) enables the tab to be mechanically secured through friction and geometric constraint as it passes through. The tab is held in place by the channel walls without requiring any additional adhesive materials, achieving assembly stability while eliminating material and processing costs associated with adhesives.
Data Source
AI summary
An insulation spacer for a battery cell. The insulation spacer includes a first wall face and a second wall face distributed opposite to each other along a thickness direction of the insulation spacer. The first wall face is configured to face an electrode assembly of the battery cell. The insulation spacer further includes a first edge wall located between the first wall face and the second wall face. A first opening is created on the first wall face or the first edge wall. A second opening is created on the second wall face. A first channel is created inside the insulation spacer. One end of the first channel communicates to the first opening. Another end of the first channel communicates to the second opening. The insulation spacer is configured to enable passage of a tab.