Battery Electrode Tab Hard-Edge Structure Against Warping
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Solution Overview
Problem
The tabs in battery electrode plates are prone to folding or warping after die-cut forming, which can affect the electrochemical quality of the battery and increase the risk of battery failure.
Innovation Solution
The electrode plate design includes a tab with a foil uncoating region and a second treating area at the edge of the outer side, where the thickness of the second treating area is greater than or equal to the thickness of other areas, forming a hard edge that enhances the strength and hardness of the tab.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tab is formed by die-cut forming a foil uncoating region, then the tab can be separated from the active material coating region, but the tab becomes prone to folding or warping due to reduced structural support
Solution Approach 1:
The patent applies local quality by creating a treating area with different properties than the rest of the current collector. Specifically, the treating area has increased thickness (1.05-1.2 times the average) and is free of active material coating, providing localized structural reinforcement exactly where the tab needs support while maintaining ease of manufacture through targeted processing
2Strength
If the thickness of the current collector is increased throughout to prevent tab folding, then the strength and hardness improve, but the manufacturing complexity and material usage increase
Solution Approach 1:
Rather than uniformly increasing the thickness of the entire current collector, the patent applies local quality by creating a treating area with selectively increased thickness (1.05-1.2 times the average thickness) only at specific locations where tabs are formed. This localized reinforcement provides the necessary tab strength while avoiding the manufacturing complexity and material waste associated with thickening the entire current collector structure
3Strength
If the tab edge is reinforced with a treating area of greater thickness, then the hardness and strength of the tab edge increase, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by performing the treating process (such as laser treatment, flame treatment, or chemical treatment) on the current collector before the active material coating is applied. This preliminary treatment creates the hardened, thickened treating area in advance, and subsequent die-cut forming naturally exposes this treated area at the tab edges. This approach integrates the reinforcement into the existing manufacturing sequence without adding significant complexity
Data Source
AI summary
An electrode plate of the battery includes an active material coating region and a tab, and the tab includes a foil uncoating region; and the foil uncoating region includes three outer sides, a second treating area is provided at an edge of at least one of the three outer sides, and a thickness of the second treating area is greater than or equal to a thickness of other areas, excluding the second treating area, of the foil uncoating region. The tab of the electrode plate has an increased strength, thereby eliminating a hidden factor of causing failure of a battery due to warping of a tab, and thus solving a problem of causing failure of a battery cell or affecting an electrochemical quality of a battery due to insufficient strength of a tab to fold or warp, and significantly improving an electrochemical quality and safety of a battery.