Battery Cell Tab Insulator Layout for Housing Isolation Control
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Solution Overview
Problem
Battery cells experience short circuits due to the tab overlapping with the housing, which is caused by the tab's elastic restoring force after assembly, leading to safety concerns during use.
Innovation Solution
The battery cell design incorporates an insulator with a concave portion surrounding the tab, which isolates it from the housing and prevents contact, using a first insulator that abuts against the tab's peripheral surface and a second insulator that further isolates the tab from the housing, reducing the likelihood of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tab is allowed to extend freely to the opening, then the assembly process is simple, but the tab may contact the housing due to elastic restoring force causing short circuit
Solution Approach 1:
An insulator is introduced as an intermediary component between the tab and the housing. The insulator includes a concave portion that accommodates the tab, preventing direct contact between the tab and housing while avoiding interference with the tab's elastic restoring force. This mediator structure maintains assembly simplicity while ensuring reliable short circuit prevention.
2Reliability
If the tab is constrained to prevent contact with housing, then short circuit risk is reduced, but the structure becomes more complex
Solution Approach 1:
The insulator is designed with a thin-walled cup-shaped structure featuring a concave portion. This thin-film-like structure provides effective isolation between the tab and housing while maintaining structural simplicity. The concave portion flexibly accommodates the tab without requiring complex constraint mechanisms.
3Reliability
If the insulator completely surrounds the tab, then isolation effectiveness is improved, but the tab's elastic restoring force may be restricted
Solution Approach 1:
The insulator features a localized concave portion rather than complete surrounding. This local quality approach allows the insulator to provide isolation effectiveness where needed (at the critical contact points with housing) while leaving the tab's elastic restoring force unrestricted in other areas. The concave portion is strategically positioned to accommodate the tab without over-constraint.
Data Source
AI summary
Embodiments provide a battery cell, a battery, an electric apparatus, and a manufacturing method and system of battery cell. In those embodiments, the battery cell includes a housing, an electrode assembly, and an end cover assembly. The housing provides an opening. The electrode assembly is disposed in the housing. The electrode assembly includes a body portion and a tab. The tab extends from an end of the body portion to the opening. The electrode assembly includes a first electrode plate, a second electrode plate, and a separator. The first electrode plate and the second electrode plate each have a coated area and an uncoated area. A part of the electrode assembly corresponding to the coated areas of the first electrode plate and the second electrode plate is the body portion. The uncoated area of the first electrode plate or the second electrode plate forms the tab.