Cleavage Flaking Lithium Ion Battery Tab-Free Design
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Solution Overview
Problem
The existing methods for assembling lithium ion batteries, such as lamination and winding types, are inefficient, prone to short-circuits due to metal tabs piercing the diaphragm, and occupy valuable space, leading to reduced energy density.
Innovation Solution
A cleavage flaking type lithium ion battery design where electrode substrates are coated and cut into strips with a blank region protruding, allowing direct connection to the battery shell or metal contacts, eliminating the need for tabs and enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional lamination or winding assembling methods with metal tabs are used, then the battery structure is conventional and easy to manufacture, but the production efficiency is low and the energy density per unit volume is reduced due to tab occupation
Solution Approach 1:
The invention extracts and removes the metal tab component from the battery structure. The electrode substrate itself is designed with a protruding portion that directly serves as the connection terminal, eliminating the need for separate metal tabs. This extraction resolves the contradiction by removing the space-occupying tab while simplifying the overall structure and improving production efficiency.
Solution Approach 2:
The invention merges the electrode substrate function with the terminal connection function. The protruding portion of the electrode substrate integrates both the electroactive material carrier and the electrical connection interface, combining multiple functions into a single component. This merging eliminates the need for separate tabs and simplifies the assembling process.
2Reliability
If metal tabs are used to connect electrodes, then the electrical connection is established, but the tabs easily puncture the diaphragm causing short-circuit firing
Solution Approach 1:
The invention extracts the harmful metal tab component that causes diaphragm puncture. By using the electrode substrate's own protruding portion as the connection terminal, the invention eliminates the sharp metal edges that penetrate the diaphragm, thereby preventing short-circuit firing while maintaining reliable electrical connection.
Solution Approach 2:
The invention converts the potential harm of metal tabs puncturing diaphragms into a benefit by using the electrode substrate material itself (which is inherently safe for diaphragm contact) to create the protruding connection portion. This transformation eliminates the safety hazard while maintaining the necessary electrical connection function.
3Quantity of substance
If metal tabs are used for electrode connection, then the electrical connection is achieved, but the tabs occupy a lot of effective spaces inside the shell
Solution Approach 1:
The invention extracts the space-occupying metal tab component and replaces it with the electrode substrate's own protruding portion. This elimination of redundant components frees up significant internal volume within the battery shell, allowing for increased active material content and thereby improving energy density per unit volume.
Solution Approach 2:
The invention merges the terminal function into the electrode substrate structure, eliminating the need for separate tab components. This integration removes the volume occupied by tabs and their associated fastening structures, maximizing the effective space available for energy-storing materials.
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
This design simplifies the manufacturing process, prevents short-circuits, and significantly increases energy density by eliminating the need for tabs, improving production efficiency and safety.
Implementation Method 1
strips are formed by laser cutting or die cutting
Implementation Method 2
the blank region is connected with the battery shell or the metal contact arranged the battery shell in advance through ultrasound or laser
Implementation Method 3
the blank region is connected with the battery shell or the metal contact arranged the battery shell in advance through ultrasound or laser
Data Source
AI summary
Disclosed is a cleavage flaking type lithium ion battery and a preparation method thereof. The cleavage flaking type lithium ion battery includes a battery shell and a winding electric core; the winding electric core includes a battery pole piece which includes a coating region and a blank region adjacent to the coating region coated with an electrode material, and the blank region is directly connected with the battery shell or with a metal contact on the battery shell. The battery pole piece is directly connected with the battery shell, which omits the traditional process in which pole pieces need to be overlaid and welded with tabs, thereby effectively simplifying the process flow, improving the automation degree of production, avoiding a risk of short-circuit firing caused by a fact that a diaphragm is punctured when the tabs are wrapped in the pole pieces and improving the safety performance of the battery.