Battery Tab Bending Space Optimization

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Solution Overview

Problem

Secondary battery tabs often experience excessive bending, leading to short circuits due to insufficient space, or reduced battery core utilization due to excessive space, resulting in suboptimal performance.

Innovation Solution

A battery design with a tab bending space between the core and cover plate, where the height of this space is optimized to be greater than D/10 and less than 3D/4, allowing for a tab bending angle between 45° and 135°, and including a tab transition region and protection sheet to prevent short circuits and enhance core utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the tab bending space is excessively small, then the tab is pressed in the small space, but the tab bending angle cannot meet requirements resulting in short circuit

Engineering Contradiction:

Improveshort circuit preventionVSAvoidtab bending angle control

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent applies parameter changes by optimizing the tab bending space height to a specific range (D/10 to 3D/4, where D is core thickness) and controlling the tab bending angle within 45° to 135°. These parameter specifications ensure the tab has sufficient space to bend without being pressed, preventing short circuits while maintaining reliable electrical connection.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If the bending space is excessively large, then the tab bending angle requirements are met, but utilization of the height of the battery core is reduced resulting in decreased capacity

Engineering Contradiction:

Improvetab bending angle controlVSAvoidbattery core capacity

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The patent resolves this contradiction by setting the tab bending space height within the optimized range of D/10 to 3D/4 of the core thickness D. This parameter optimization ensures sufficient bending space for tabs to achieve 45° to 135° bending angles while minimizing the space occupied, thereby maximizing the utilization of battery core height and maintaining high core capacity.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the tab bending space height is not optimized, then manufacturing is simpler, but either short circuit or reduced capacity occurs

Engineering Contradiction:

Improvespace design simplicityVSAvoidbattery safety and capacity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent establishes specific parameter ranges for tab bending space height (D/10 to 3D/4) and tab bending angle (45° to 135°) to resolve the contradiction between manufacturing simplicity and battery performance. These parameter specifications provide clear manufacturing guidelines that ensure both ease of production and reliable battery safety with optimal capacity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces the tab bending space as an intermediary element between the core and cover plate. This intermediary space with optimized height serves as a buffer zone that accommodates tab bending while preventing direct contact between tabs and the cover plate, thereby preventing short circuits without requiring complex manufacturing processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20230207982A1battery

Publication Date: 2023.06.29 BYD CO LTD

AI summary

A battery includes a casing, a cover plate, and a core. The cover plate is configured to cover the casing, and the core is disposed in the casing. A plurality of tabs is connected between the core and the cover plate. A tab bending space is formed between the cover plate and the core, and the tabs are disposed in the tab bending space. A height of the tab bending space along a first direction is greater than D/10 and less than 3D/4, and D is a thickness of the core.