Battery Tab Limiting Sheet for Reverse Insertion Prevention
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Solution Overview
Problem
Existing secondary batteries face safety issues due to tabs being reversely inserted or deformed, leading to internal short circuits, which can cause smoking, fires, or explosions.
Innovation Solution
A tab limiting sheet is introduced between the cell body and tab bodies, featuring elastic elements and support parts that prevent tab contact and reverse insertion by absorbing deformation and maintaining a safe distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tabs are made with certain lengths according to machining technologies, then manufacturing is feasible, but tabs may be bumped and impacted during usage, resulting in extrusion deformation and reverse insertion into battery cell
Solution Approach 1:
The patent introduces a tab limiting sheet as an intermediary component disposed between the tab and the battery cell body. This limiting sheet includes a limiting portion that physically restricts the tab's movement range, preventing reverse insertion into the cell while maintaining the tab's required length for manufacturing feasibility.
Solution Approach 2:
The tab limiting sheet is pre-installed on the battery cell body before the tab is fully assembled. This preliminary action establishes the limiting structure in advance, so that when the tab is installed, its movement is immediately constrained by the pre-positioned limiting sheet, preventing deformation and reverse insertion.
2Volume of stationary object
If tabs are folded into certain space, then battery packaging is achieved, but tabs may contact with opposite polarity pole pieces, resulting in internal short circuit
Solution Approach 1:
The tab limiting sheet acts as an insulating intermediary between the tab and the battery cell body. The limiting portion extends toward the tab and creates a physical barrier that prevents the tab from contacting pole pieces of opposite polarity, thereby eliminating the short circuit risk while maintaining compact battery packaging.
Solution Approach 2:
The patent adds a spatial dimension solution by extending the limiting portion of the limiting sheet toward the tab in a direction that creates three-dimensional spacing. This dimensional approach separates the tab from potential contact points with opposite polarity components, preventing short circuits within the compact battery volume.
3Object-affected harmful factors
If insulating pallet with soft material is used, then tab contact is prevented, but the solution requires adaptive deformation which may not provide sufficient mechanical constraint
Solution Approach 1:
The tab limiting sheet is made from composite materials that combine insulation properties with appropriate mechanical strength. The limiting portion is constructed to provide both electrical insulation and rigid mechanical constraint, preventing tab deformation and reverse insertion through its structural integrity rather than relying solely on soft material deformation.
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
Prevents internal short circuits by ensuring tab bodies remain spaced, reducing the risk of contact and insertion, thereby enhancing battery safety and stability.
Implementation Method 1
The elastic element produces a corresponding deformation under pressure to absorb part of a deformation caused by a position movement of the two tab bodies
Data Source
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AI summary
A tab limiting sheet (1), a top cover assembly (3), and a battery are provided. The tab limiting sheet (1) includes a first mounting part (11), a connecting assembly (12), and a second mounting part (16). The connecting assembly (12) includes an elastic element (121) and a first support element (122). The elastic element (121) is connected between the first mounting part (11) and the second mounting part (16). The first support element (122) includes a first supporting part (1221) connected with the first mounting part (11) and the second mounting part (16) connected with the second mounting part (16). When the elastic element (121) is in a natural state, the first supporting part (1221) and the second supporting part (1222) are spaced. When the elastic element (121) is squeezed to a maximum deformation state, the first supporting part (1221) is tight.