Battery Cell Tab Isolation Structure Against Impact Short Circuits
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Solution Overview
Problem
Battery cells face safety hazards due to tab deformation during external impacts, leading to potential short circuits and safety risks.
Innovation Solution
Incorporating an isolation member with a channel and tab layers that are sized and configured to reduce deformation and friction, ensuring the tab is insulated and isolated from the body portion, thereby preventing insertion and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tab is led directly out from the body portion without isolation, then the structure is simple and easy to manufacture, but the tab may deform and insert into the body portion during external impacts, causing short circuits and safety hazards
Solution Approach 1:
An isolation member is introduced as an intermediary component between the tab and the body portion. This isolation member includes a channel that guides the tab and prevents direct contact between the tab and the body portion, thereby eliminating the short circuit hazard while maintaining structural clarity.
Solution Approach 2:
The tab is divided into multiple tab layers that are stacked and constrained within the channel of the isolation member. This segmentation allows each layer to be independently managed and restrained, preventing deformation and insertion into the body portion during external impacts.
2Stability of the object's composition
If the channel size is reduced to constrain the tab layers, then the tab deformation is reduced, but the frictional forces between tab layers and channel walls increase, causing wear
Solution Approach 1:
The channel dimensions are precisely controlled with width W1 and height H1 satisfying specific relationships with the total thickness T1 of the tab layers (0.5mm ≤ W1-T1 ≤ 4mm and H1 ≥ T1). This parameter optimization ensures the tab layers are constrained enough to maintain morphology but have sufficient clearance to minimize frictional wear.
3Loss of substance
If the channel width is increased to reduce friction, then wear is reduced, but the tab layers become uncompressed and may deform more easily
Solution Approach 1:
The channel width W1 is precisely controlled to satisfy 0.5mm ≤ W1-T1 ≤ 4mm, where T1 is the total thickness of the tab layers. This optimized width provides just enough space to reduce frictional wear while maintaining sufficient constraint to prevent excessive tab deformation during operation.
4Loss of substance
If the channel height is increased to accommodate tab layers, then friction is reduced, but the space efficiency and energy density decrease
Solution Approach 1:
The channel height H1 is optimized to satisfy H1 ≥ T1, where T1 is the total thickness of the tab layers. This minimal sufficient height accommodates the tab layers with just enough clearance to reduce friction while minimizing the space occupied by the isolation member, thereby maximizing energy density.
Data Source
AI summary
A battery cell includes a housing, an electrode assembly, and an isolation member. The housing is provided with an electrode lead-out member. The electrode assembly is accommodated in the housing, where the electrode assembly includes a body portion and a tab led out of an end face of the body portion. At least a portion of the isolation member is disposed between the electrode lead-out member and the end face of the body portion, where the isolation member is provided with a channel, and the tab passes through the channel and is electrically connected to the electrode lead-out member.