Nickel-Plated Battery Tab Plate Sealing Against Corrosion
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Solution Overview
Problem
Lithium secondary batteries are prone to corrosion and short circuits due to the reaction between the tab plate and electrolyte, exacerbated by moisture ingress from environmental changes, which can lead to safety issues.
Innovation Solution
A battery pack design featuring a tab plate made of 95% nickel and an impermeable adhesive tape between the tab plate and the battery cell, preventing electrolyte and moisture contact, thereby reducing corrosion and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tab plate is made of conventional material, then manufacturing cost is reduced, but corrosion resistance deteriorates due to reaction with electrolyte and moisture
Solution Approach 1:
The tab plate is constructed as a composite structure consisting of a base plate and a nickel plating layer. The nickel plating (5 μm to 50 μm thickness) provides superior corrosion resistance against electrolyte and moisture, while the base plate maintains structural integrity. This composite approach achieves enhanced reliability without prohibitive manufacturing costs, as selective plating is more economical than using solid nickel throughout.
Solution Approach 2:
The invention specifies precise parameter ranges for the nickel plating thickness (5 μm to 50 μm) to optimize the balance between corrosion protection and manufacturing cost. This parameter control ensures sufficient barrier protection against electrolyte penetration while avoiding excessive material usage and cost escalation.
2Reliability
If the tab plate is in direct contact with the battery cell, then electrical connection is simplified, but short circuit risk increases due to electrolyte penetration
Solution Approach 1:
An adhesive tape is introduced as an intermediary component between the tab plate and the battery cell casing. This adhesive tape serves as a barrier that prevents electrolyte from penetrating between the tab plate and the cell, thereby eliminating the short circuit risk. The adhesive tape is specifically designed to be impermeable to electrolyte while maintaining electrical connectivity through the tab plate's nickel-plated surface.
Solution Approach 2:
The adhesive tape functions as a flexible thin film barrier that conforms to the interface between the tab plate and battery cell. This thin film approach provides effective electrolyte sealing without adding significant structural complexity or rigid constraints to the assembly.
3Reliability
If the nickel plating thickness is increased, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
The invention defines an optimized nickel plating thickness range of 5 μm to 50 μm that achieves sufficient corrosion protection while controlling material consumption. This parameter specification balances the competing demands of reliability and material efficiency, avoiding both under-plating (insufficient protection) and over-plating (excessive cost).
Solution Approach 2:
The nickel plating is applied selectively to the tab plate surface where corrosion protection is most critical, rather than uniformly throughout the entire component. This localized application of high-quality nickel plating focuses material resources on the interface most exposed to electrolyte and moisture, achieving maximum protection with minimum material usage.
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 design significantly reduces corrosion and short circuits by minimizing the reaction between the tab plate and electrolyte, enhancing the battery's durability and safety under varying environmental conditions.
Implementation Method 1
The adhesive tape may be impermeable to an electrolyte and moisture.
Implementation Method 2
the tab plate including nickel... significantly reduces corrosion and short circuits by minimizing the reaction between the tab plate and electrolyte
Data Source
AI summary
A battery pack includes a battery cell including at least one terminal portion, a battery case accommodating the battery cell, a tab plate that is in contact with the at least one terminal portion, the tab plate including nickel, and an adhesive tape between the tab plate and the battery cell.