Wound Battery Tab Roll Structure for Faster Electrolyte Infiltration
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Solution Overview
Problem
Jelly-roll batteries face challenges with low liquid injection efficiency due to dense connections between flattened tabs, leading to slow electrolyte infiltration and increased production complexity, as well as the risk of internal short-circuits from tab deformation during use.
Innovation Solution
The battery design features first and second electrode plates with tab rolls composed of multiple separated tab plates, allowing for increased voids and rapid electrolyte infiltration, while maintaining overcurrent capability, and includes insulation layers to reduce short-circuit risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tabs are flattened to form welding positions, then the welding reliability is improved, but the liquid injection efficiency deteriorates due to dense connections blocking electrolyte infiltration
Solution Approach 1:
The patent divides the continuous tab structure into multiple separated tab plates within the tab rolls. This segmentation creates gaps between individual tab plates, allowing electrolyte to infiltrate through these spaces while the tab rolls maintain their structural integrity for reliable welding. The tab rolls are composed of multiple tab plates arranged in a rolled configuration, creating channels for electrolyte flow.
2Reliability
If the tabs are flattened to form welding positions, then the welding reliability is improved, but the production process complexity increases due to additional insulation tape wrapping
Solution Approach 1:
The patent combines the insulation function with the tab roll structure itself. The tab rolls are designed to provide both electrical insulation and structural support simultaneously, eliminating the need for separate insulation tape wrapping steps. The rolled configuration of multiple tab plates inherently provides the necessary insulation while maintaining welding capability.
3Reliability
If the tabs are flattened densely, then the welding reliability is improved, but the risk of internal short-circuit increases due to tab deformation and contact with housing
Solution Approach 1:
The patent segments the tab structure into multiple separated tab plates within rolled configurations. This segmentation prevents dense flattening while maintaining welding reliability, as each tab plate remains structurally independent. The gaps between tab plates prevent deformation-induced contact with the housing, eliminating the internal short-circuit risk associated with dense tab flattening.
Solution Approach 2:
The patent uses the rolled configuration of multiple tab plates as a flexible structure that maintains its shape and prevents deformation. The tab rolls act as a protective shell that keeps the tabs separated and prevents them from contacting the housing, thereby preventing internal short-circuits while maintaining welding capability.
Data Source
AI summary
A battery includes a wound body, and the wound body includes a first electrode plate, a separator, and a second electrode plate that are stacked and wound. The first electrode plate includes a first current collector and a first active material layer provided on the first current collector. The first current collector includes, along a width direction of the first current collector, a first portion provided with a first active material layer and a second portion not provided with the first active material layer. The second portion is located on a side of the first portion perpendicular to a winding direction and forms a plurality of layers of first tab rolls around a central axis of the wound body. At least one layer of the first tab rolls includes a plurality of first tab plates separated from each other.