Battery Cell Tab Assembly Layout for Higher Energy Density
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Solution Overview
Problem
Lithium-ion batteries face low energy density due to the space occupied by dummy tabs, which also increase manufacturing complexity and reduce efficiency.
Innovation Solution
A battery cell design with a tab assembly where the tab adhesive wraps around the overlapping portion of the outer and dummy tab groups, reducing the need for folding and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If dummy tabs are folded before placing the battery cell into the case, then space occupied by dummy tabs is reduced, but manufacturing steps increase and manufacturing efficiency decreases
Solution Approach 1:
The dummy tabs are pre-welded to the body in advance during the tab assembly formation process, and the tab adhesive is pre-applied to wrap around the overlapping portion. This preliminary arrangement eliminates the need for subsequent folding operations, reducing manufacturing steps while effectively minimizing the space occupied by dummy tabs.
2Volume of moving object
If dummy tabs are folded to reduce space, then space occupation is reduced, but manufacturing complexity increases
Solution Approach 1:
The tab assembly is pre-configured with the dummy tabs welded to the body and the tab adhesive applied to wrap around the overlapping portion before the battery cell is placed into the case. This preliminary arrangement simplifies the overall manufacturing process by eliminating subsequent folding steps and reducing process complexity.
3Ease of manufacture
If tab adhesive is arranged on the outer tab (conventional method), then manufacturing is simpler, but space between body and top sealing position is increased
Solution Approach 1:
The tab adhesive is arranged to wrap around the overlapping portion of the outer tab and dummy tab group in a three-dimensional configuration, rather than being placed flat on the outer tab surface. This spatial arrangement reduces the distance from the body to the top sealing position while maintaining manufacturing feasibility through the pre-configured tab assembly structure.
Data Source
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AI summary
The present application discloses a battery cell, a lithium ion battery manufacturing method, and a lithium ion battery. The battery cell comprises a body and tab assemblies; each tab assembly comprises a dummy tab group, an outer tab, and a tab adhesive; the dummy tab group comprises at least one dummy tab connected to the body; the outer tab is conductively connected to the dummy tab group; in a projection in the thickness direction of the body, the outer tab and the dummy tab group partially overlap to form an overlapping portion, and the tab adhesive is wrapped around at least part of the overlapping portion; two tab assemblies are provided, and the two tab assemblies are staggered in the width direction of the body. The distance between the tab adhesives and the body is closer, the dummy tabs do not need to be folded, and a top sealing process step is directly performed at the positions of the tab adhesives after the battery cell is placed into a packaging housing, so that the space occupied by the tab assemblies between the body and the top sealing positions can be reduced, improving the energy density of the lithium ion battery, and the production steps of the lithium ion battery can be simplified, improving the production efficiency of the lithium ion battery.