Composite Battery Substrate With Buried Tabs for Low-Resistance Contact

The tab is embedded within the substrate structure, with the support layer wrapping around the tab to form an integrated configuration. This nesting approach enhances adhesive force and contact resistance by ensuring intimate contact between the tab and substrate, while the tab serves dual functions as both electrical conductor and structural reinforcement element.

The substrate employs a composite structure combining a support layer (such as polymer or metal foil) with metal layers deposited on its surfaces. This composite construction provides both mechanical strength and electrical conductivity, resolving the contradiction between structural reliability and manufacturing complexity by integrating multiple material functions into a unified substrate system.

The support layer is configured to provide enhanced contact specifically at the tab interface region, rather than uniformly increasing material throughout the entire substrate. This localized approach ensures adequate adhesive force and contact resistance where needed, while minimizing overall material consumption to preserve battery energy density.

The embedded tab configuration allows the support layer to wrap around the tab, creating intimate contact with minimal additional material. This nesting approach achieves reliable electrical and mechanical contact without requiring large tab areas or excessive substrate material, thereby maintaining high energy density while ensuring adequate adhesive force.