Battery Tab Shaping Plate Structure for Short-Circuit Prevention
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Solution Overview
Problem
Electric vehicle batteries are prone to internal and external short circuits, which can lead to safety issues such as smoke and explosion, particularly due to contact between the negative and positive tabs and electrodes.
Innovation Solution
The battery design includes an electrode assembly with first and second tabs that are bent around a shaping plate, which is thermally fused to the cap plate assembly, preventing the tabs from being inserted into the electrode assembly and thus avoiding short circuits between the tabs and electrodes, while also incorporating an explosion-proof valve and insulation to enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tabs are allowed to extend freely into the electrode assembly, then the electrical connection is simplified, but the risk of internal short circuit increases
Solution Approach 1:
The shaping plate serves as an intermediary component between the tabs and the electrode assembly. It provides a structured interface that guides the tabs into proper positions while preventing them from contacting the electrode plates directly, thus maintaining electrical connection functionality while eliminating short circuit risk.
Solution Approach 2:
The shaping plate extracts and isolates the tabs from the electrode assembly interior. By bending the tabs around the shaping plate and securing them externally, the potentially harmful elements (tabs) are removed from the dangerous zone (electrode assembly interior) while maintaining their necessary electrical function.
2Reliability
If the tabs are bent and fixed to the cap plate assembly, then the risk of internal short circuit is reduced, but the structural complexity increases
Solution Approach 1:
The shaping plate merges multiple functions into a single component: it provides mechanical support for bending the tabs, serves as a mounting structure for securing the tabs to the cap plate assembly, and acts as a physical barrier preventing tab contact with electrode plates. This integration reduces the number of separate components needed.
Solution Approach 2:
The shaping plate performs multiple functions simultaneously: structural support, tab positioning, short circuit prevention, and mechanical attachment. This multi-functionality justifies the added structural element by eliminating the need for multiple separate safety and positioning components.
3Strength
If the shaping plate is thermally fused to the cap plate assembly, then the fixation is strengthened, but the manufacturing process becomes more complex
Solution Approach 1:
The thermal fusion process replaces mechanical fastening methods (such as screws, clips, or adhesives) with a direct thermal bonding process. This substitution creates a stronger, more integrated connection between the shaping plate and cap plate assembly, while the process can be automated in manufacturing to offset the added complexity.
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
This design effectively prevents short circuits and enhances the safety performance of the battery by maintaining the bent shape of the tabs and providing a mechanism for pressure relief, thereby reducing the risk of smoke and explosion.
Implementation Method 1
the shaping plate is fixed and thermally fused to the cap plate assembly
Implementation Method 2
an explosion-proof valve is arranged on the cap plate assembly
Data Source
AI summary
The present disclosure relates a battery, including an electrode assembly, a first tab, a second tab, a cap plate assembly, a first electrode terminal, a second electrode terminal and a shaping plate. The electrode assembly includes a first electrode plate, a second electrode plate and a separator arranged between the first electrode plate and the second electrode plate; each of the first electrode terminal and the second electrode terminal is arranged on the cap plate assembly; the first electrode terminal is connected to the first electrode plate through the first tab; the second electrode terminal is connected to the second electrode plate through the second tab; the shaping plate is arranged between the cap plate assembly and the electrode assembly, and each of the first tab and the second tab is bent around the shaping plate; the shaping plate is fixed and thermally fused to the cap plate assembly.