Jelly Roll Connector Insulation Patch for Solder Residue Blocking
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Solution Overview
Problem
Lithium batteries face internal short circuits and reduced service life due to soldering residues falling into the jelly roll assembly during the tab soldering process, leading to premature degradation.
Innovation Solution
The use of insulation patches that cover the connector and tab areas, extending to the side surface, prevents soldering residues from entering the jelly roll pack, while also counteracting expansion forces during charging and discharging to maintain flatness and improve electrolyte entry, thus enhancing the service life of the energy storage device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tab soldering is performed on the jelly roll assembly, then electrical connection is achieved, but soldering residues fall into the jelly roll pack causing internal short circuit
Solution Approach 1:
An insulation patch is introduced as an intermediary component between the connector and the jelly roll pack. The insulation patch covers the connector and extends to the side surface of the jelly roll, forming a protective barrier that prevents soldering residues from falling into the jelly roll pack while maintaining electrical connection functionality.
Solution Approach 2:
The insulation patch is applied beforehand to cover the connector area where soldering residues may fall. This preliminary protective measure creates a barrier before the harmful effect (residue falling) can occur, preventing internal short circuits without affecting the soldering process itself.
2Reliability
If insulation patch is added to cover connector and tab areas, then prevention of soldering residues entering jelly roll is achieved, but device structure becomes more complex
Solution Approach 1:
The insulation patch is implemented as a thin film or flexible insulating material that can be easily applied to cover the connector and extend along the jelly roll side surface. This thin-film approach provides effective protection against soldering residues while adding minimal structural complexity and maintaining a compact device design.
3Duration of action of stationary object
If insulation patch extends to side surface to cover connector and tab, then service life is prolonged, but manufacturing process becomes more complex
Solution Approach 1:
The insulation patch is applied in advance during the assembly process, before the device enters service. This preliminary action ensures that the protective barrier is already in place to prevent soldering residues from causing damage, thereby extending service life without requiring complex post-manufacturing processes or specialized equipment.
Data Source
AI summary
An energy storage device and an electric device are provided in the disclosure. The energy storage device includes a jelly roll assembly and a connector. The jelly roll assembly includes at least one jelly roll. Each of the at least one jelly roll has multiple tabs arranged in a thickness direction of the tabs after winding an electrode sheet. The jelly roll has a first side surface and a first end surface. The multiple tabs are bent at roots of the multiple tabs and attached to the first end surface. The multiple tabs have a connection surface away from the first end surface. The connector is disposed on the connection surface and connected with the multiple tabs. The jelly roll assembly further includes a first insulation patch. The first insulation patch adheres to and covers a surface of the connector away from the first end surface, and extends to the first side surface.