Battery Cell Tab Protection Structure for Impact and Lead Alignment
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Solution Overview
Problem
Conventional battery cells lack protection for the electrode tab, making them vulnerable to damage from external impacts and having inaccuracies in electrode lead positioning, which can lead to stress and potential short circuits.
Innovation Solution
A battery cell design incorporating a tab protection module within the cell case that includes a lead positioning guide and positioning guide insert portions to securely position and protect the electrode lead, dispersing external forces and enhancing dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the electrode tab is surrounded only by the cell case without a separate protective structure, then the cell case structure is simple, but the electrode tab is vulnerable to external force and impact damage
Solution Approach 1:
The protective structure is divided into separate modular components: a tab protection module that specifically protects the electrode tab, and a cell case that accommodates the electrode assembly. This segmentation allows the protection function to be added without redesigning the entire cell case structure.
Solution Approach 2:
A tab protection module is introduced as an intermediary component between the electrode tab and the external environment. This module includes a lead positioning guide that couples to the electrode lead and guides its position, while the tab protection module itself covers and protects the electrode tab from external forces.
2Manufacturing precision
If there is no separate mechanical structure for fixing the electrode lead, then the cell case structure is simple, but the dimensional accuracy of electrode lead positioning is insufficient
Solution Approach 1:
The lead positioning guide is designed with predetermined positioning features that guide the electrode lead to its correct position before final assembly. The positioning guide insert portion in the cell case is pre-configured to receive and secure the lead positioning guide, ensuring accurate positioning is established early in the assembly process.
Solution Approach 2:
A lead positioning guide is introduced as an intermediary mechanical structure between the electrode lead and the cell case. This guide includes positioning features that couple to the electrode lead and interface with the cell case, providing precise dimensional control for lead positioning without requiring complex direct fixing structures.
3Reliability
If the electrode tab is exposed without protection, then the cell structure is simple, but the electrode tab is susceptible to stress and potential short circuits from external impacts
Solution Approach 1:
The tab protection module is installed beforehand to cushion and protect the electrode tab from external impacts. The module includes structural features that absorb and distribute impact forces before they can reach the vulnerable electrode tab, preventing stress concentration and potential short circuits.
Solution Approach 2:
The tab protection module serves as a protective intermediary between external forces and the electrode tab. It includes a lead positioning guide that couples to the electrode lead and provides mechanical protection, while the tab protection module body covers the electrode tab, creating a protective barrier that enhances reliability.
Data Source
AI summary
Disclosed is a battery cell, which includes an electrode assembly including a cell body and an electrode tab provided to at least one side of the cell body, a cell case configured to accommodate the electrode assembly therein, an electrode lead coupled to the electrode tab and extending from the cell case, and a tab protection module accommodated in the cell case and configured to cover at least a portion of the electrode tab, the tab protection module including a lead positioning guide and a corresponding positioning guide insert portion adapted to receive the positioning guide insert portion, wherein the positioning guide insert portion is configured to couple to the electrode lead to guide a position of the electrode lead relative to the cell case.