Battery Cell Tab Bending Structure to Prevent Layer Bifurcation

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Solution Overview

Problem

Bending tabs in battery cells leads to safety issues due to potential bifurcation and increased risk of short-circuiting.

Innovation Solution

Incorporating a second bending portion on the tab that protrudes towards the main body part, forming a local binding and increasing separation resistance between tab layers to prevent bifurcation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If tabs are bent to save space and improve energy density, then space utilization is improved, but safety performance deteriorates due to potential bifurcation and short-circuiting

Engineering Contradiction:

Improvespace utilizationVSAvoidsafety performance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent applies local quality by creating a second bending portion with a specific protruding shape at a localized region of the tab. This local structural modification causes the tab layers to converge and bind together at the protruding portion, increasing separation resistance only where needed to prevent bifurcation, while maintaining the overall bent configuration for space savings.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent utilizes curvature by designing the second bending portion with a specific curved protruding shape. This curved structure naturally guides and converges the tab layers toward the center of the protrusion, creating a binding effect that prevents bifurcation while maintaining the bent tab configuration for compactness.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Volume of moving object

If tabs are bent into complex shapes, then space is saved, but manufacturing complexity increases

Engineering Contradiction:

Improvespace occupationVSAvoidmanufacturing complexity

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by dividing the tab structure into distinct functional portions: a first bending portion for space-saving configuration and a second bending portion with a protruding shape for safety. This segmentation allows each portion to be optimized independently, with the second bending portion designed as a simple protruding feature that can be easily formed during standard tab manufacturing processes.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12537232B2Battery cell, battery, electrical apparatus, and manufacturing method for battery cell

Publication Date: 2026.01.27 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

A battery cell, a battery, an electrical apparatus, and a manufacturing method for a battery cell are disclosed. The battery cell includes an electrode assembly, and the electrode assembly includes a main body part and a tab extending from the main body part. The tab includes a first bending portion and a straight portion, and the straight portion is connected to the main body part through the first bending portion; a second bending portion is formed on the straight portion, and the second bending portion protrudes towards the side of the main body part. The arrangement of the second bending portion generates a protruding deformation towards the side of the main body part, which makes the layers of the tab close together, forming a local binding of the tab, and increasing the resistance to separation between the layers of the tab, thereby improving the safety of the battery.