Battery Cell Tab Insulation Layer for Joint Corrosion Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In existing battery cell products, the joint between the tab and the electrode assembly is exposed, leading to a risk of corrosion due to burrs piercing the packaging bag, which conventional tab adhesives cannot adequately protect.
Innovation Solution
A battery cell design featuring a first insulation layer with a free end that automatically covers the joint between the tab and the electrode assembly, reducing the risk of corrosion without increasing the battery cell's thickness or affecting its performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional tab adhesive is used to bond to the tab, then the tab is protected from corrosion, but the joint between the tab and electrode assembly remains exposed due to processing conditions
Solution Approach 1:
The insulation layer extends in the thickness direction beyond the tab surface, creating a three-dimensional protective structure. This dimensional extension allows the insulation layer to cover the joint area between the tab and electrode assembly that cannot be reached by conventional two-dimensional tab adhesive application, solving the coverage problem while maintaining corrosion protection.
Solution Approach 2:
The insulation layer is pre-formed with an extended portion that protrudes beyond the tab surface before assembly. This preliminary preparation ensures that the protective insulation is already in position to cover the joint area, eliminating the need for precise post-assembly adjustment and ensuring protection is established before the battery cell is sealed.
2Reliability
If the insulation layer is extended to cover the joint area, then protection is improved, but the device complexity increases
Solution Approach 1:
The insulation layer is integrated as a single continuous component that combines both the surface bonding function (through the adhesive layer on the tab) and the joint protection function (through the extended portion covering the joint area). This merging eliminates the need for separate protective components and simplifies the overall structure while achieving enhanced protection.
Solution Approach 2:
The extended insulation layer serves multiple functions simultaneously: it provides electrical insulation, protects the joint area from corrosion, and maintains structural integrity. This multi-functionality reduces the need for additional protective components and simplifies the overall battery cell design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively protects the joint between the tab and the electrode assembly from corrosion, preventing burrs from piercing the packaging bag and ensuring the battery cell's integrity and functionality.
Implementation Method 1
The first insulation layer includes a substrate layer and an adhesive layer disposed on the substrate layer. The adhesive layer bonds to the first tab.
Data Source
AI summary
A battery cell includes an electrode assembly and a packaging bag configured to accommodate the electrode assembly. The electrode assembly includes a first electrode plate, a separator, and a second electrode plate that are stacked. A first tab is disposed on the first electrode plate. The first tab protrudes from the packaging bag. The first tab includes a connecting portion accommodated in the packaging bag. A first insulation layer is disposed on the connecting portion. The first insulation layer includes a free end towards the electrode assembly.