Battery Cell Tab Structure for Safer End-Cover Assembly
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Solution Overview
Problem
Existing battery cell designs face safety risks due to the potential for tabs to be inserted into the body part during external impacts, leading to short circuits, and reducing tab lengths to improve safety complicates the assembly process.
Innovation Solution
The battery cell design features a first tab with a longer protruding length and a second tab with a shorter protruding length, where the second tab's length is less than the first tab's, and an isolation member with a channel to reduce the risk of tab insertion and simplify assembly, while maintaining effective electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tab length is reduced to improve safety, then the risk of tab insertion into the body part is reduced, but the assembly process becomes more difficult
Solution Approach 1:
The patent divides the tabs into two segments with different length characteristics: a first tab with a first length and a second tab with a second length. This segmentation allows each tab to be optimized independently - the first tab can be longer for easier assembly while the second tab can be shorter for improved safety, resolving the contradiction between assembly ease and safety
Solution Approach 2:
The patent applies asymmetry by making the first tab and second tab have different lengths (L1 and L2 respectively). This asymmetric design breaks the conventional symmetric approach where both tabs are of equal length, allowing the system to simultaneously achieve easier assembly (with the longer first tab) and improved safety (with the shorter second tab)
2Ease of manufacture
If the tab length is increased to simplify assembly, then the assembly process becomes easier, but the risk of tab insertion into the body part increases
Solution Approach 1:
The patent segments the tab structure into two distinct tabs with different lengths, allowing the first tab to be optimized for assembly ease (longer length L1) while the second tab is optimized for safety (shorter length L2), thus resolving the contradiction between assembly ease and safety
Solution Approach 2:
The patent applies local quality by giving different length characteristics to different parts of the tab structure. The first tab has a first length suitable for assembly, while the second tab has a second length suitable for safety, allowing each local region to have the quality needed for its specific function
Data Source
AI summary
A battery cell includes a housing, a first end cover assembly, a second end cover assembly and an electrode assembly. Openings are provided on ends of the housing opposite to each other. The first end cover assembly and the second end cover assembly are configured to respectively cover two openings of the housing. The electrode assembly includes a body part, a first tab and a second tab. The first tab extends from a first end face of the body part facing the first end cover assembly and is configured to be connected with the first end cover assembly. The second tab extends from a second end face of the body part facing the second end cover assembly and is configured to be connected with the second end cover assembly.