Battery Cell Tab Insulator Layout for Higher Energy Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Insulating tapes on the tabs of wound battery cells, when attached entirely to connectors, affect bonding force and stability, leading to increased thickness and reduced energy density.
Innovation Solution
The battery cell design includes insulators that do not entirely overlap with connectors, with specific arrangements and configurations such as gaps, notches, and binding layers to enhance bonding force and stability, thereby reducing overlapping regions and increasing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If insulators are entirely attached to connectors, then bonding force is improved, but thickness of battery cell increases and energy density decreases
Solution Approach 1:
The insulator is segmented into multiple sections along its length, with different sections having different overlapping relationships with the connector. Specifically, the first insulator has a first section that overlaps with the connector and a second section that does not overlap with the connector, creating a distributed attachment pattern that optimizes both bonding and thickness.
Solution Approach 2:
Different sections of the insulator have different local properties regarding connector overlap. The first section is designed to overlap with the connector to provide bonding force, while the second section is designed not to overlap to reduce thickness and improve energy density. This local differentiation resolves the contradiction between bonding strength and cell thickness.
2Strength
If insulators are entirely attached to connectors, then bonding force is improved, but stability of battery cell deteriorates
Solution Approach 1:
The insulator structure is segmented such that only part of it (the first section) overlaps with the connector, while another part (the second section) remains non-overlapping. This segmentation prevents the insulator from being entirely attached to the connector, thereby maintaining stability while still providing adequate bonding force through the overlapping section.
Solution Approach 2:
The second section of the insulator is extracted from the connector overlap region, removing the portion that would cause stability issues. This extraction allows the insulator to maintain bonding force through the first section while avoiding the stability deterioration caused by complete attachment.
3Strength
If insulators entirely overlap with connectors, then bonding force is improved, but energy density decreases
Solution Approach 1:
The insulator is divided into overlapping and non-overlapping sections, where only the first section contributes to connector bonding. The second section extends beyond the connector without overlapping, reducing the total overlapping region and thereby increasing energy density while maintaining necessary bonding force through the first section.
Solution Approach 2:
Different sections of the insulator have different local overlap qualities with the connector. The first section has high overlap quality for bonding, while the second section has zero overlap to maximize energy density. This local quality differentiation resolves the contradiction between bonding force and energy density.
Data Source
AI summary
A battery cell includes a battery cell body, at least two tabs, a first connector and at least two insulators. The first connector is configured to fasten a tail end of an electrode assembly to an outer surface of the battery cell body; the at least two tabs include a first tab and a second tab, and the at least two insulators include a first insulator and a second insulator, where first ends of the first insulator and the second insulator are all provided on the battery cell body, a second end of the first insulator covers part of the first tab, and a second end of the second insulator covers part of the second tab; and in a width direction of the battery cell body, the first insulator is provided close to the first connector, where at least part of the first insulator is located outside the first connector.