Corrugated Battery Foil Tabs for Shock and Vibration Relief
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Solution Overview
Problem
Battery cells are susceptible to shock and vibration, leading to undesirable failure modes such as increased cell resistance, additional heat generation, and the production of undesirable byproducts that can cause thermal runaway, which existing technologies fail to adequately address.
Innovation Solution
The implementation of corrugated foil tabs with alternating peaks and troughs, coupled to the cathode and anode of battery cells, provides enhanced flexibility and strain relief, incorporating a polymer and ceramic insulating coating to absorb shocks and vibrations, and is designed for various battery cell configurations including pouch, prismatic, and cylindrical designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flat foil tabs are used in battery cells, then the manufacturing process is simple, but the tabs are susceptible to shock and vibration causing tab damage and failure
Solution Approach 1:
The patent applies corrugation (a form of curvature) to the foil tab structure, creating alternating peaks and troughs along the tab length. This curved geometry provides mechanical flexibility and shock absorption capabilities that flat tabs lack, directly improving tab durability while maintaining electrical conductivity functionality
2Reliability
If rigid tab structures are used, then manufacturing is easier, but the tabs cannot absorb shocks and vibrations leading to increased cell resistance and heat generation
Solution Approach 1:
The corrugated tab structure transforms the rigid, static tab design into a dynamic structure that can flex and deform in response to shocks and vibrations. The alternating peaks and troughs allow the tab to absorb mechanical energy through controlled deformation, preventing failure modes associated with rigid tabs while remaining manufacturable through standard corrugation processes
3Reliability
If foil tabs lack insulating coatings, then the manufacturing process is simpler, but the tabs are prone to short circuits and electrical failures
Solution Approach 1:
The patent applies insulating coatings (such as polymer or ceramic materials) to the corrugated foil tab surface, creating a composite structure that combines the electrical conductivity of the metal foil with the insulating properties of the coating. This prevents short circuits and electrical failures while the corrugated geometry provides mechanical protection, achieving both electrical and mechanical reliability
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 corrugated foil tabs enhance the mechanical strength and durability of battery cells, reducing the likelihood of tab damage and associated failures, thereby improving the robustness and reliability of battery cells by effectively absorbing shocks and vibrations, thus preventing undesirable failure modes.
Implementation Method 1
enhanced tabs coupled to battery cells to help to absorb shock and vibration
Implementation Method 2
enhanced tabs coupled to battery cells to help to absorb shock and vibration
Implementation Method 3
The foil tabs may have an insulating coating to prevent shorting between adjacent tabs
Data Source
AI summary
Some embodiments disclosed herein are directed to battery cells with corrugated foil tabs. Some embodiments may include a battery cell comprising a cathode, an anode and a corrugated foil tab coupled to the cathode or the anode, wherein the corrugated foil tab has a length in a first plane, includes alternating peaks and troughs in a second plane along the length of the corrugated foil tab, and has a width in a third plane, and wherein the first plane, second plane, and third plane are orthogonal to each other. Other embodiments may be disclosed or claimed.