Battery Tab Notch Sealing to Save Space and Improve Reliability
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Solution Overview
Problem
Conventional electrochemical devices face issues with large internal space occupation, complex sealing structures, high cost, and low reliability due to through-hole sealing methods, leading to significant energy density loss.
Innovation Solution
The electrochemical device employs a notch in the housing for leading out the tab, filled with a sealing material such as an elastic sealing material or binder, which simplifies the sealing process and enhances reliability while minimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a through-hole sealing structure is used to lead out the electrode post, then the electrode can be connected to external devices, but the internal space is occupied and energy density is reduced
Solution Approach 1:
The housing is divided into a shell and a cover, with the tab led out through the cover rather than through a through-hole in the main housing body. This segmentation allows the sealing function to be localized to the cover area, freeing up internal space in the main housing while maintaining reliable sealing at the tab exit point.
2Reliability
If a through-hole sealing structure with insulating pad is used, then the electrode post is sealed and electrically isolated, but the structure becomes complicated and processing cost increases
Solution Approach 1:
The sealing function and electrical insulation function are merged into a single sealing member that surrounds the tab. This integrated sealing member eliminates the need for separate insulating pads and complex multi-component sealing structures, simplifying the overall design while maintaining both sealing reliability and electrical isolation.
Solution Approach 2:
The sealing member is designed to perform multiple functions simultaneously: it provides sealing to prevent electrolyte leakage, provides electrical insulation to isolate the tab, and provides mechanical support for the tab exit. This multi-functionality reduces the number of separate components needed and simplifies the overall sealing structure.
3Ease of manufacture
If a through-hole sealing structure is used, then the electrode post can be sealed, but the processing cost becomes high and reliability is low
Solution Approach 1:
The sealing member is pre-formed with the tab already positioned within it, and the sealing structure is designed to be assembled in a straightforward manner before final housing assembly. This preliminary preparation simplifies the manufacturing process and ensures proper sealing configuration, improving both ease of manufacture and reliability.
Data Source
AI summary
An electrochemical device includes an electrode assembly and a housing for accommodating the electrode assembly. The housing includes a first housing body and a second housing body fixedly connected to the first housing body. A notch is provided on at least one of the first housing body or the second housing body. The electrode assembly includes a tab. The tab protrudes out of the housing from the notch. The notch is filled with a sealing material.