Curable Resin Protective Layer for Battery Tab Insulation
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Solution Overview
Problem
Conventional non-aqueous electrolyte secondary batteries with protective tapes are prone to internal short circuits due to foreign matter contamination, leading to increased battery temperature and impaired insulating properties.
Innovation Solution
A non-aqueous electrolyte secondary battery design featuring a protective layer with a curable resin substrate that covers exposed portions of the electrodes, preventing foreign matter from causing short circuits and maintaining insulating properties even after heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin tape with adhesive layer is used as protective layer, then the insulating property is improved, but foreign matter can penetrate through and cause internal short circuit leading to heat generation and insulating property impairment
Solution Approach 1:
The protective layer is constructed as a composite material comprising a base layer and a heat-resistant layer with different functional properties. The base layer provides general insulation while the heat-resistant layer (with higher glass transition temperature) provides enhanced protection against foreign matter penetration and maintains insulating properties under thermal stress, preventing the short circuit issues experienced with single-material resin tapes.
Solution Approach 2:
The protective layer applies different material properties to different regions/layers: the base layer uses a resin with certain insulating properties, while the heat-resistant layer uses a resin with higher glass transition temperature and better thermal stability. This local differentiation of material quality ensures that the critical interface regions (where foreign matter penetration is most likely) have enhanced protection while maintaining overall insulating performance.
2Ease of manufacture
If conventional protective tape is used, then manufacturing is simple, but temperature control after internal short circuit is poor leading to continuous heat generation
Solution Approach 1:
The two-layer composite structure with differentiated thermal properties allows the heat-resistant layer to act as a thermal barrier during short circuit events. This composite construction maintains ease of manufacture (both layers can be applied sequentially using standard coating techniques) while providing superior temperature control and preventing the continuous heat generation problem of conventional single-layer tapes.
Solution Approach 2:
The heat-resistant layer is applied beforehand to the critical regions (exposed portions of current collector and electrode tab) to provide pre-established thermal protection. This prior cushioning ensures that when foreign matter causes a short circuit, the protective layer is already in place to suppress temperature rise and prevent catastrophic failure, rather than relying on post-failure responses.
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 battery effectively suppresses temperature rises following internal short circuits, outperforming conventional designs by maintaining insulating properties and preventing continuous heat generation.
Implementation Method 1
the insulating property of the substrate or the adhesive layer may be impaired, and the heat generation may continue
Implementation Method 2
the protective layer includes a substrate comprising a curable resin
Data Source
AI summary
A positive electrode for this non-aqueous electrolyte secondary battery is provided with: a positive electrode current collector; a positive electrode active material layer formed on the positive electrode current collector; a positive electrode tab connected to an exposed portion at which the positive electrode current collector is exposed and on which the positive electrode active material layer is not formed; and a protective layer covering the exposed portion and the positive electrode tab on the exposed portion. The protective layer is composed of a base material including a curable resin.