Battery Tab Spacing Design Prevents Tearing and Compression
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Solution Overview
Problem
The existing battery designs face issues where the spacing between the pole core and the solder joint affects the tab's bending, leading to either tearing or compression, resulting in capacity loss and safety risks due to electrode contact.
Innovation Solution
A battery design where the spacing between the pole core and the solder joint is determined by the pole core thickness, tab bending angle, and tab protection plate width, ensuring a balanced tab free region to prevent tearing and compression, thus maintaining battery safety and capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the spacing between the pole core and the solder joint is designed small, then the tab free region is reduced, but the tab is easily pulled and torn after bending causing capacity loss
Solution Approach 1:
The patent applies parameter changes by establishing a specific mathematical relationship for the spacing L1 based on pole core thickness D, tab bending angle A, and tab protection plate width d1. The formula L1 = D/2 × tan(A) + d1/2 transforms the spacing from a fixed value to a dynamically calculated parameter that adapts to different battery configurations, thereby preventing tab tearing while maintaining manufacturing precision.
Solution Approach 2:
The tab protection plate serves as an intermediary element between the pole core and the solder joint. This protective structure provides mechanical support to the tab during bending operations, distributing the stress and preventing direct pulling on the tab-solder joint connection, thus maintaining tab integrity without requiring excessive spacing.
2Reliability
If the spacing between the pole core and the solder joint is designed large, then the tab movable length is increased, but the bending space increases leading to capacity loss
Solution Approach 1:
The patent uses parameter changes to optimize the spacing L1 to a precise calculated value rather than using a large fixed spacing. This ensures the tab has sufficient movable length for bending while minimizing the bending space required, thereby preventing capacity loss from excessive empty space in the battery cell.
Solution Approach 2:
The solution introduces dynamic characteristics by allowing the spacing to be calculated based on the tab bending angle A, which can vary within a range (45°≤A≤135°). This dynamic approach enables the spacing to adapt to different bending requirements while maintaining optimal battery space utilization.
3Reliability
If the bending space is increased to accommodate tab movement, then the tab can bend without compression, but the battery capacity is reduced
Solution Approach 1:
The patent applies parameter changes by calculating the optimal spacing L1 that provides just enough bending space for the tab to move through its required angle range without compression. This precise calculation eliminates the need for excessive bending space, maximizing the battery's active material volume and thus its capacity.
Solution Approach 2:
The solution implements partial action by providing only the minimum necessary bending space required for safe tab operation. Rather than allocating excessive space, the patent calculates and provides precisely the amount of space needed based on the tab dimensions and bending angle, avoiding capacity loss from unused volume.
4Reliability
If the tab movable length is increased to prevent tearing, then the bending space required increases, but this leads to tab compression and electrode contact
Solution Approach 1:
The tab protection plate acts as an intermediary that provides mechanical support during tab bending. This protective structure enables the tab to have sufficient movable length for bending operations without requiring excessive free space, thereby preventing both tab tearing and the harmful effect of tab compression that could cause electrode contact.
Solution Approach 2:
The patent uses parameter changes to optimize the spacing L1 to a precise value that balances tab mobility with space constraints. This calculated spacing provides just enough room for the tab to bend to the required angle without becoming too long and risking compression, thus preventing electrode contact while maintaining tab integrity.
Data Source
AI summary
A cell has at least one pole core. Each pole core has a plurality of tabs. The plurality of tabs are converged and then soldered to a cover plate of a battery to form a solder joint. When the pole core is parallel to the cover plate before convergence or after the pole core is unfolded, a spacing between the pole core and the solder joint is determined by a thickness of the pole core, a tab bending angle of the tab, and a width of a tab protection plate at the solder joint.