Battery Tab Insulating Layer for Impact Protection

The patent implements a nested multi-layer packaging structure where the packaging film is enclosed within an insulating layer, which itself is protected by an impact-resistant layer. This nested configuration provides progressive protection against impact while maintaining a compact overall structure, resolving the contradiction between enhanced safety and structural complexity.

The patent employs composite material construction by combining the packaging film with insulating layers and impact-resistant layers having different mechanical properties. The insulating layer provides electrical isolation while the impact-resistant layer absorbs mechanical shocks, creating a composite structure that simultaneously improves safety and distributes functional complexity across specialized layers.

The insulating layers are pre-formed with protective portions that extend over the connecting regions before assembly. This preliminary preparation of the insulating layers allows for standardized mass production of the protective components, which can then be systematically assembled into the battery structure, reducing overall manufacturing complexity despite the enhanced safety features.

The insulating layers are designed with non-uniform thickness and extended protective portions specifically at the connecting regions where tabs emerge, rather than uniformly throughout. This localized enhancement of insulating properties at critical areas provides targeted protection against piercing while minimizing additional material usage and manufacturing complexity in non-critical regions.