Battery Tab Insulating Structure for Short-Circuit Prevention
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Solution Overview
Problem
In currently available batteries, the tab free end can easily contact the inner wall of the casing, leading to short circuits due to the butt seam between the insulating member and the insulating bracket, which compromises battery safety.
Innovation Solution
A single battery design that incorporates a tab blocked structure on the first insulating member, forming a first accommodating space with the first terminal to limit the movable range of the tab free end, preventing it from contacting the casing and eliminating the need for tab cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating member and insulating bracket are provided between the cover plate and electrode assembly, then contact between tabs and casing is prevented, but a butt seam exists between the insulating member and insulating bracket creating a risk of tab protrusion and contact with casing
Solution Approach 1:
The patent merges the insulating member and insulating bracket into a single integrated insulating structure. This eliminates the butt seam between separate components while maintaining the insulating function, thereby preventing tab protrusion and contact with the casing without the complexity of multiple assembled parts.
Solution Approach 2:
The insulating structure is segmented into functional zones: a first insulating portion that contacts the cover plate, a second insulating portion that contacts the electrode assembly, and a blocking portion that prevents tab protrusion. This segmentation allows each zone to perform its specific function while forming an integrated whole without butt seams.
2Reliability
If tab cutting is performed to prevent tab free end contact with casing, then short circuit risk is reduced, but production process complexity and cost increase
Solution Approach 1:
The patent extracts the tab blocking function from the manufacturing process and incorporates it into the insulating structure design. The blocking portion of the insulating structure passively prevents tab free end contact with the casing, eliminating the need for active tab cutting operations while maintaining short circuit prevention.
Solution Approach 2:
The insulating structure with its blocking portion serves the dual function of electrical insulation and tab containment. The structure itself provides the protection against short circuits without requiring external manufacturing interventions like tab cutting, making the system self-sufficient.
3Reliability
If a tab blocked structure is added to the insulating member, then tab free end contact with casing is prevented, but the insulating member structure becomes more complex
Solution Approach 1:
The insulating member has different local qualities: the first insulating portion provides electrical insulation from the cover plate, the second insulating portion insulates from the electrode assembly, and the blocking portion specifically prevents tab protrusion. Each local region is optimized for its specific function, making the overall structure efficient despite increased complexity.
Solution Approach 2:
The insulating member is designed as a multi-functional component that simultaneously provides electrical insulation, mechanical support, and tab containment. The blocking portion is integrated into the same component that provides insulation, making the insulating member a universal solution for multiple problems rather than requiring separate components.
Data Source
AI summary
A single battery includes a casing, a first cover plate, a first terminal, an electrode assembly, and a first insulating member. The casing includes a first opening. The first cover plate seals and is installed on the first opening. The first terminal is installed on the first cover plate. The electrode assembly is arranged in the casing and has a first tab extending from a side close to the first cover plate. The first tab is fixedly connected to the first terminal and is formed with a first tab free end. The first insulating member is installed on a side of the first cover plate close to the electrode assembly. The first insulating member is provided with a tab blocked structure. A side of the first terminal close to the electrode assembly and the tab blocked structure form a first accommodating space.