Current-Collecting Tab Geometry to Prevent Snagging in Electrodes
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Solution Overview
Problem
Rectangular current collection tabs in electrochemical cell electrodes are prone to damage due to right-angled corners, leading to snagging and jamming during transport, which disrupts production and reduces efficiency.
Innovation Solution
The current collection tabs are designed with a distal portion featuring a fold or pre-cut line with weakenings such as slits or scratches, allowing the tab to deform around an obstacle without forming a right angle, reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If current-collecting tabs are made thicker to improve mechanical strength and handling, then the solid electrolyte layer becomes thinner in the tab region, which reduces ion conductivity and increases internal resistance
Solution Approach 1:
The patent applies local quality by creating a thickness gradient in the solid electrolyte layer: the layer is thicker in the active electrode regions where ion conductivity is critical, and thinner in the tab regions where mechanical strength is prioritized. This spatial variation in thickness optimizes both ion transport in functional areas and structural integrity in support areas, resolving the contradiction between mechanical strength and ion conductivity.
2Stability of the object's composition
If a support structure is added to prevent bending of flexible batteries, then device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent merges the support structure function with the current-collecting tab itself. The tabs are designed with increased thickness and extended length to serve dual purposes: electrical current collection and mechanical support for the flexible battery structure. This integration eliminates the need for separate support components, reducing device complexity while maintaining structural stability.
3Volume of moving object
If the solid electrolyte layer is made thinner overall to reduce battery thickness, then ion conductivity decreases and internal resistance increases
Solution Approach 1:
The patent implements local quality through a non-uniform solid electrolyte layer thickness distribution. The layer maintains sufficient thickness in active regions to ensure adequate ion conductivity and low internal resistance, while being thinner in inactive tab regions to reduce overall battery volume. This localized thickness optimization resolves the contradiction between compact size and ion transport performance.
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to an electrode comprising a metal sheet (1) that comprises - an active portion (3) coated with an active material; - a metal portion (4) free of active material and extending along a longitudinal edge of the metal sheet, this metal portion comprising a current-collecting tab (6) projecting from a longitudinal edge of the active portion; the current-collecting tab comprising - a proximal portion (61) connected to the metal sheet, which portion is intended to be electrically connected to a current collector; - a distal portion (62), the distal portion projecting from the proximal portion; the distal portion comprising - a first lateral edge (63); - a second lateral edge (64) facing the first lateral edge, wherein this second lateral edge converges towards the first lateral edge as it extends away from the proximal portion.