Breakable Tab Design for Battery Electrode Assembly
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Solution Overview
Problem
Existing electrode assemblies in battery packs face issues with high resistance and safety risks due to tab breakage and excessive voltage, and they have low energy density, leading to safety concerns and inefficiencies.
Innovation Solution
The electrode assembly incorporates breakable tabs with insulating layers and controlled bending parts to reduce breakage risk, enhance safety, and increase energy density by optimizing the number and arrangement of tabs, along with insulating layers to prevent electrical connections and improve space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple tabs are used for multi-channel current output, then charge and discharge rate is improved, but tab breakage risk and safety hazards increase
Solution Approach 1:
The tab is divided into multiple segments (first segment and second segment) connected at an angle less than 90 degrees. This segmentation allows the tab to flex and bend without breaking, distributing mechanical stress across multiple sections rather than concentrating it at a single point, thereby maintaining reliability while supporting multiple current output channels
Solution Approach 2:
An insulating layer is applied beforehand to the tab structure, particularly at the connection between segments and at contact points with the housing. This preventive insulation cushioning prevents electrical short circuits and reduces safety hazards before they can occur, allowing the system to maintain high productivity with multiple tabs
2Reliability
If tabs are stacked and welded for current output, then electrical connectivity is improved, but resistance increases and safety risks worsen
Solution Approach 1:
The insulating layer acts as an intermediary element between the tab and surrounding components (housing, other tabs). This intermediary prevents unwanted electrical contact and short circuits, allowing the tab structure to maintain low resistance and good connectivity without safety risks from excessive voltage or short circuits
3Ease of manufacture
If existing electrode assembly structure is used, then manufacturing is simplified, but energy density is low
Solution Approach 1:
The tab configuration parameters are changed - specifically the included angle between segments is set to less than 90 degrees, and the number of breakable tabs is controlled to be no more than half the total number of tabs. These parameter changes optimize space utilization and electrical performance, enabling higher energy density while maintaining ease of manufacture through standardized design
Data Source
AI summary
The present disclosure provides an electrode assembly including a first electrode sheet, the first electrode sheet includes a first current collector and a first tab. The first tab extends from a surface of the first electrode sheet and electrically connected with the first current collector, a plurality of tabs are provided and the number of the first tabs is q. The plurality of first tabs include a first breakable tab, the first breakable tab includes a breakable part and a first insulating layer, the first insulating layer wraps the breakable part, the breakable part includes a first segment and a second segment, the first segment is connected with the second segment, and an included angle between the first segment and the second segment is less than 90°. The number of first breakable tabs is p, and p/q≤1/2.