Battery Cell Tab Insulator Overlap Layout for Higher Bonding Force
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Solution Overview
Problem
Insulating tapes on battery cell tabs affect bonding force and stability, leading to increased thickness and reduced energy density due to complete attachment to connectors.
Innovation Solution
The insulators are arranged such that at least a part does not overlap with the connector, with specific configurations like gaps, notches, and binding layers to enhance bonding force and stability, reducing overlap regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If insulators are entirely attached to connectors, then bonding force is improved, but thickness of battery cell increases and energy density decreases
Solution Approach 1:
The insulator is divided into multiple sections along its length, with different sections having different overlapping relationships with the connector. Specifically, the first insulator has a first overlapping section that overlaps with the connector and a second overlapping section that does not overlap with the connector, creating a segmented structure that optimizes both bonding force and thickness.
Solution Approach 2:
Different sections of the insulator have different local properties regarding their relationship with the connector. The first overlapping section provides strong bonding where needed, while the second overlapping section reduces overall thickness by not overlapping with the connector, achieving local optimization of both bonding force and compactness.
2Strength
If insulators are entirely attached to connectors, then bonding force is improved, but stability of battery cell deteriorates due to upwarp
Solution Approach 1:
The insulator's overlapping relationship with the connector is segmented into multiple sections rather than being continuous. This segmentation prevents the insulator from being entirely attached to the connector, thereby preventing upwarp while maintaining bonding force in critical areas.
Solution Approach 2:
Instead of complete attachment of the insulator to the connector, only a partial attachment is implemented through the first overlapping section. This partial action is sufficient to provide the necessary bonding force while avoiding the harmful effect of complete attachment that causes upwarp and stability issues.
3Strength
If insulators are entirely attached to connectors, then bonding force is improved, but energy density decreases due to increased thickness
Solution Approach 1:
The insulator structure is segmented to reduce overall thickness by having portions that do not overlap with the connector. This reduction in thickness increases the volume available for active materials, thereby improving energy density while maintaining necessary bonding force in overlapping sections.
Solution Approach 2:
The insulator exhibits local quality variations where different sections have different thickness profiles relative to the connector. This allows the battery cell to achieve compact overall dimensions for higher energy density while maintaining adequate bonding force in specific local regions where overlapping occurs.
Data Source
AI summary
A battery cell includes a battery cell body, at least two tabs, a first connector and at least two insulators. The first connector is configured to fasten a tail end of an electrode assembly to an outer surface of the battery cell body; the at least two tabs include a first tab and a second tab, and the at least two insulators include a first insulator and a second insulator, where first ends of the first insulator and the second insulator are all provided on the battery cell body, a second end of the first insulator covers part of the first tab, and a second end of the second insulator covers part of the second tab; and in a width direction of the battery cell body, the first insulator is provided close to the first connector, where at least part of the first insulator is located outside the first connector.