Battery Cell Tab Separator Layout for Short-Circuit Insulation
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Solution Overview
Problem
Existing electrochemical battery cells face reliability issues due to the risk of short-circuiting caused by poor insulation and tightly packed electrical connections, which reduces the battery cell's capacity and compactness.
Innovation Solution
The introduction of a first metallic separation device interposed between each pair of adjacent electrical connection tabs, which is attached to at least one of the tabs and extends between the lower and upper edges, allowing for easier welding of electrical connectors and reducing the need to bend tabs, thus optimizing space and capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the cover exerts stress on the connection to maximize space and electrical capacity, then the space utilization and electrical capacity are improved, but the risk of short-circuiting increases due to poor insulation and tightly packed connections
Solution Approach 1:
The patent introduces an insulating coating on the electrical connection tabs and an insulating barrier between adjacent tabs. This intermediary insulating layer acts as a mediator that prevents direct contact between conductive elements, thereby eliminating the short-circuit risk while allowing the connections to remain tightly packed for maximum space utilization and electrical capacity.
2Volume of moving object
If the tabs are bent back toward the stack to maximize space, then the space utilization is improved, but the manufacturing complexity and risk of short-circuiting increase
Solution Approach 1:
Instead of bending the tabs toward the stack to save space, the patent inverts the approach by applying insulating coating to the tabs and positioning them in a way that maintains insulation without bending. This eliminates the need for complex bending operations while preventing short-circuits through the insulating barrier, thereby reducing manufacturing complexity.
3Ease of manufacture
If the tabs are kept straight to simplify manufacturing, then the manufacturing complexity is reduced, but the space utilization and electrical capacity decrease
Solution Approach 1:
The insulating coating on the tabs serves as an intermediary that enables the tabs to remain straight for simplified manufacturing while still achieving high space utilization and electrical capacity. The insulation layer allows close positioning of straight tabs without short-circuit risk, thereby maintaining both manufacturing simplicity and high electrical capacity.
4Volume of moving object
If the separator is made thinner to reduce space, then the space utilization is improved, but the insulation performance and reliability decrease
Solution Approach 1:
The patent employs composite insulation solutions combining insulating coating on the tabs with insulating barriers positioned between adjacent tabs. This composite approach provides superior insulation performance that allows the use of thinner separators for improved space utilization while maintaining high reliability through the multi-layer insulating system.
Data Source
AI summary
The invention relates to an electrochemical bundle comprising a plurality of stacks each including a first polarity electrode, a second polarity electrode, a first separator and a second separator. Each first polarity electrode comprises an electrical connection tab.The electrochemical bundle comprises a first metallic separator interposed between each pair of adjacent electrical connection tabs. The first separator is attached to at least one of said electrical connection tabs.The first separator extends, between each pair of adjacent electrical connection tabs, between a lower edge and an upper edge.The upper edges of the first separator are substantially flush with the upper edges of the electrical connection tabs.