Asymmetrical Battery Tab Seal for Drop Protection and Venting

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Solution Overview

Problem

Traditional batteries are susceptible to breaches in their enclosures due to device drops or over-pressurization, and they often fail to effectively vent gases during over-pressurization scenarios.

Innovation Solution

The battery enclosure features an asymmetrical tab seal with a first portion designed for efficient venting during over-pressurization and a second portion for maintaining integrity during device drops, utilizing differences in mechanical strength, material composition, and melting temperature to protect against both scenarios.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional battery seal is used, then the battery enclosure is protected against breaches during device drops, but the battery cannot effectively vent gases during over-pressurization scenarios

Engineering Contradiction:

Improveenclosure integrity during dropsVSAvoidgas venting capability

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The seal is divided into multiple segments with different mechanical strengths: a first seal portion with higher mechanical strength to prevent breaches during drops, and a second seal portion with lower mechanical strength to enable gas venting during over-pressurization. This segmentation allows each portion to perform its specific function independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the seal are assigned different local qualities (mechanical strengths) to perform different functions. The first seal portion has higher mechanical strength for structural protection, while the second seal portion has lower mechanical strength for pressure relief, creating local functional differentiation within the seal structure.

Inventive Principle:

Principle #3Local quality

2Strength

If a strong seal is used to prevent breaches during device drops, then enclosure integrity is improved, but the seal cannot release pressure during over-pressurization scenarios

Engineering Contradiction:

Improveseal mechanical strengthVSAvoidinternal pressure relief

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The seal is segmented into a first seal portion with higher mechanical strength to maintain enclosure integrity during drops, and a second seal portion with lower mechanical strength that can fail or deform to release internal pressure during over-pressurization events.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The potential harmful effect of over-pressurization is converted into a beneficial pressure relief mechanism by designing the second seal portion to fail at a controlled point, transforming the risk of explosion into a safe venting pathway.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Stress or pressure

If a weak seal is used to enable gas venting during over-pressurization, then pressure relief is improved, but the seal cannot protect against breaches during device drops

Engineering Contradiction:

Improvepressure venting efficiencyVSAvoidseal mechanical strength

Core Design Contradiction:

Stress or pressureVSStrength

Solution Approach 1:

The seal is divided into a first seal portion with higher mechanical strength for drop protection and a second seal portion with lower mechanical strength for efficient gas venting, allowing each segment to optimize its performance for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different local qualities are assigned to different portions of the seal: the first seal portion has higher mechanical strength properties for structural protection, while the second seal portion has lower mechanical strength properties optimized for pressure release.

Inventive Principle:

Principle #3Local quality

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 asymmetrical tab seal effectively prevents enclosure breaches during drops while enabling efficient gas venting during over-pressurization, enhancing the battery's performance in both scenarios.

Implementation Method 1

the first seal portion includes a first characteristic that enables a first mechanical strength of the first seal portion, and the second seal portion includes a second characteristic that enables a second mechanical strength of the second seal portion such that the second mechanical strength is greater than the first mechanical strength

Methodology Applied

Scientific EffectMechanical strength differential:

Implementation Method 2

The first strong portion and the first weak portion differ in size, shape, or material composition such that the first strong portion includes a greater mechanical strength, a greater melting temperature, or both relative to the first weak portion

Methodology Applied

Scientific EffectMelting temperature differential: Melting

Data Source

PatentUS20250379305A1Asymmetrical battery seal system and method

Publication Date: 2025.12.11 APPLE INC

AI summary

The present disclosure is directed to a battery including an asymmetrical tab sealant, which includes a stronger seal portion around a tab in a tab opening of an enclosure (e.g., pouch) of the battery towards a cup side of the battery, and a weaker seal portion around the tab in the tab opening of the enclosure towards a non-cup side of the enclosure. Various characteristics may be employed to generate the stronger seal portion and the weaker seal portion, such as material characteristics, melting temperature characteristics, thickness characteristics, and so on.