Ceramic-Coated Battery Electrode Tabs to Prevent Short Circuits
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Secondary battery electrodes often experience short circuits due to uncoated portions, which can lead to electrical failures and hinder smooth tab welding processes.
Innovation Solution
A secondary battery electrode design where a ceramic layer is applied on uncoated portions of both positive and negative electrodes, forming a coupling portion that can be welded to a tab, thereby preventing short circuits and facilitating smooth welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrode active material is applied on an electrode plate, then the electrode functionality is improved, but uncoated portions may cause short circuits
Solution Approach 1:
The electrode plate surface is divided into multiple coating regions with different materials: a first coating layer of electrode active material and a second coating layer of ceramic material applied on uncoated portions. This segmentation allows different areas to serve different functions - the active material provides electrochemical functionality while the ceramic layer prevents short circuits in uncoated areas.
Solution Approach 2:
Different coating materials are applied to different regions of the electrode plate based on local requirements. The electrode active material is applied where electrochemical activity is needed, while the ceramic material is applied on uncoated portions specifically to prevent short circuits. This local quality approach optimizes both functionality and safety.
2Reliability
If a ceramic layer is applied on uncoated portions to prevent short circuits, then reliability is improved, but the tab welding process becomes more complex
Solution Approach 1:
The ceramic layer is applied on uncoated portions of the electrode plate before the tab welding process. This preliminary action ensures that short circuit prevention is already in place before welding operations begin, allowing the welding process to proceed without additional complexity or risk of short circuits during assembly.
Solution Approach 2:
The ceramic layer serves as an intermediary material between the electrode plate and potential short circuit paths. It provides electrical insulation on uncoated portions while allowing the tab welding process to proceed normally on coated portions, mediating between the need for short circuit prevention and the requirements of the welding process.
3Ease of manufacture
If uncoated portions are left on the electrode plate, then manufacturing simplicity is maintained, but short circuits occur inside the cell
Solution Approach 1:
The uncoated portions on the electrode plate, which initially represent a manufacturing simplicity advantage but pose a short circuit risk, are converted into a beneficial configuration by applying a ceramic coating layer. This transforms the potentially harmful uncoated areas into protected areas that maintain manufacturing efficiency while eliminating short circuit risks.
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
The additional ceramic layer effectively prevents short circuits and allows for seamless tab welding, enhancing the reliability and manufacturing efficiency of secondary battery electrodes.
Implementation Method 1
The processing portion may laser-process the ceramic layer.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Disclosed is an example embodiment of a secondary battery electrode including an electrode plate body including a first area and a second area, an active material layer applied on the first area, a ceramic layer applied on the second area, a coupling portion formed in the second area, and a tab welded to the coupling portion.