Battery Cell Insulation Spacer With Tab Pass-Through Hole
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Solution Overview
Problem
In battery cells, the bent part of the tab on the insulation spacer often contacts the housing, leading to short circuits and inferior safety performance due to the existing design where tabs are bent around the lateral edge of the spacer.
Innovation Solution
The introduction of a first hole in the insulation spacer allows the tab to pass through, preventing contact with the housing and enhancing safety by constraining the tab with specific dimensions and adhesives, and additional features like supporting portions and grooves to secure the tab in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tab is bent around the lateral edge of the insulation spacer, then the tab can be connected to the electrode posts, but the bent part of the tab contacts the housing causing short circuit and inferior safety performance
Solution Approach 1:
The insulation spacer is segmented by creating a first hole through it, dividing the spacer into regions that serve different functions. The tab passes through this hole rather than bending around the edge, which segments the potential contact path and prevents the bent tab from touching the housing.
Solution Approach 2:
The first hole acts as an intermediary structure that allows the tab to pass through the insulation spacer in a controlled manner. This intermediary feature guides the tab's position and prevents it from contacting the housing, thereby eliminating the short circuit risk while maintaining electrical connection functionality.
2Reliability
If a first hole is created on the insulation spacer for the tab to pass through, then the tab is prevented from contacting the housing improving safety, but the structure becomes more complex
Solution Approach 1:
The insulation spacer is segmented by creating a first hole through it, dividing the spacer into regions that serve different functions. The tab passes through this hole rather than bending around the edge, which segments the potential contact path and prevents the bent tab from touching the housing.
Solution Approach 2:
The first hole acts as an intermediary structure that allows the tab to pass through the insulation spacer in a controlled manner. This intermediary feature guides the tab's position and prevents it from contacting the housing, thereby eliminating the short circuit risk while maintaining electrical connection functionality.
3Ease of operation
If the dimension L1 of the first hole is made large to facilitate tab passage, then the tab can pass through easily, but the first hole cannot constrain the tab causing it to wobble
Solution Approach 1:
The dimensions of the first hole (L1, L4) are optimized to specific ranges relative to the tab thickness and adhesive width. By changing these parameters to appropriate values, the hole achieves dual functionality: it is large enough to allow easy tab passage but small enough to provide effective constraint and prevent wobbling.
Solution Approach 2:
The combination of the first hole structure and tab adhesive creates a composite constraint system. The hole provides geometric constraint while the adhesive provides bonding constraint, together achieving stable tab fixation that prevents wobbling while maintaining easy installation.
4Ease of manufacture
If the dimension L1/(L2+L3) is made small to simplify tab passage, then the manufacturing process is simplified, but the tab cannot be properly constrained causing it to wobble
Solution Approach 1:
The dimensions of the first hole (L1, L4) are optimized to specific ranges relative to the tab thickness and adhesive width. By changing these parameters to appropriate values, the hole achieves dual functionality: it is large enough to allow easy tab passage but small enough to provide effective constraint and prevent wobbling.
Solution Approach 2:
The combination of the first hole structure and tab adhesive creates a composite constraint system. The hole provides geometric constraint while the adhesive provides bonding constraint, together achieving stable tab fixation that prevents wobbling while maintaining easy installation.
Data Source
AI summary
An insulation spacer applicable to a battery cell. The battery cell further includes a shell, a first tab, and a second tab of an opposite polarity to the first tab. The first tab is insulated from the shell. The insulation spacer includes a first wall face and a second wall face opposite to each other along a thickness direction of the insulation spacer. A first hole that penetrates the first wall face and the second wall face is created on the insulation spacer. A direction from the first wall face to the second wall face is a first direction. The first hole is configured to be passed through by the first tab along the first direction and enable the first tab to bend to closely fit the second wall face.