Battery Electrode Layout With Overlap Insulation at Cathode Tabs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Lithium-ion batteries face a risk of short circuits due to the proximity of flexible cathode tabs to anode foils, despite the presence of a separator, which can be damaged or insufficient, leading to inefficiencies and potential electrical contact.
Innovation Solution
An extension of the anode coating layer is designed to ensure that the cathode tab's insulation cover overlaps the anode coating layer's extension, providing double insulation and preventing short circuits, even if the separator is damaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separator is used to separate cathode and anode, then electrical insulation is provided, but the separator can be damaged or insufficient, leading to short circuit risk
Solution Approach 1:
The patent applies preliminary action by extending the anode coating layer beyond the anode foil edge before assembly, creating a pre-positioned insulation barrier. This extension ensures that even if the separator is damaged or insufficient, the cathode tab insulation cover will overlap with the extended anode coating layer, providing redundant insulation protection in advance rather than relying solely on the separator's integrity during operation.
2Reliability
If a thicker separator is used to prevent short circuits, then insulation reliability improves, but battery efficiency decreases and cost increases
Solution Approach 1:
The patent applies local quality by providing enhanced insulation only in the critical region where the cathode tab extends beyond the cathode foil and may approach the anode. Instead of uniformly thickening the separator across the entire battery, the solution extends the anode coating layer locally beyond the anode foil edge, creating a targeted insulation zone that prevents short circuits at the vulnerable tab area while maintaining thin separator thickness elsewhere, thus preserving battery efficiency.
3Reliability
If manufacturing precision is improved to ensure proper electrode and separator positioning, then short circuit risk decreases, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies beforehand cushioning by creating an extended anode coating layer that protrudes beyond the anode foil edge, forming a buffer zone that compensates for potential positioning errors during assembly. This extension ensures that even if manufacturing precision varies and the cathode tab is positioned closer than ideal, the extended coating layer provides an additional insulation margin, cushioning against the risk of short circuits without requiring extremely tight manufacturing tolerances.
Data Source
Figure 1
Figure 2~3b
AI summary
The invention relates to a battery comprising at least a cathode (10) and an anode (20), the anode comprising a foil (20) covered by an anode coating layer (21), the cathode comprising a foil (10) facing the anode foil (20) and a flexible tab (14) which projects beyond the cathode foil (10) along a vertical direction (X) parallel to the cathode foil plan. Said cathode tab (14) is covered with an electrical insulation cover (12). The anode comprises an extension (22) of the coating layer (21) beyond the anode foil (20), along the vertical direction (X). Said extension (22) is designed so that the cathode tab insulation cover (12) overlaps the extremity of said extension (22) of the anode coating layer (21).