Dual-Tab Electrode Assembly for Battery Capacity Retention
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Solution Overview
Problem
Conventional laminated batteries experience capacity loss due to tab breakage during manufacturing and use, leading to reduced energy density and performance.
Innovation Solution
The electrode assembly includes extended tab portions for both positive and negative electrode plates, with main and backup tabs connected in parallel to ensure continuous operation even if the main tabs break, reducing internal resistance and increasing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single tab structure is used, then device complexity is reduced, but reliability deteriorates due to tab breakage during manufacturing and use
Solution Approach 1:
The tab structure is segmented into main tab and backup tab portions. Each electrode plate has its tab divided into two separate functional parts: the main tab for primary current collection and the backup tab for redundancy. This segmentation allows the system to maintain reliability through diversification of the current collection path without significantly increasing overall structural complexity.
Solution Approach 2:
The backup tab is prepared in advance during manufacturing, positioned and connected to the electrode plate before any potential breakage occurs. This preliminary preparation ensures that when the main tab fails during manufacturing or use, the backup tab is already in place and can immediately take over the current collection function, maintaining battery operation without interruption.
2Reliability
If backup tabs are added for each electrode plate, then reliability is improved through redundancy, but device complexity increases due to additional connections
Solution Approach 1:
Multiple backup tabs from different electrode plates are merged and connected together to form a common backup tab assembly. Similarly, multiple main tabs are connected to form a common main tab assembly. This merging approach reduces the number of individual connections required compared to providing separate backup connections for each electrode plate, thereby reducing overall device complexity while maintaining the reliability benefits of redundancy.
Solution Approach 2:
The backup tab structure serves multiple functions: it acts as a redundant current collection path when main tabs break, provides additional welding surface area for improved electrical connection, and can serve as a structural support element. This multi-functionality reduces the need for separate dedicated backup components, thereby reducing overall device complexity.
3Reliability
If tab portions are extended for backup, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The electrode plate structure is designed with different local qualities: the main tab area has optimized dimensions and positioning for primary current collection, while the backup tab area has different dimensions and positioning characteristics optimized for redundancy and ease of connection. This local differentiation allows each tab portion to be manufactured with appropriate precision requirements specific to its function, rather than requiring uniform high precision across the entire tab structure.
Solution Approach 2:
The backup tab is designed with slightly excessive length and width compared to the minimum required for electrical connection. This excessive dimension provides a tolerance buffer during manufacturing, allowing for greater positioning variability without compromising connection reliability. The extended dimensions ensure that even with manufacturing variations, the backup tab will maintain adequate contact area and electrical connection.
Data Source
AI summary
An electrode assembly includes a number of positive electrode plates, a number of separators, and a number of negative electrode plates. The positive electrode plates, the separators, and the negative electrode plates are stacked sequentially. The positive electrode plate has an extended first tab portion and second tab portion. The first tab portions of the positive electrode plates are stacked and electrically connected to form a main positive electrode tab, and the second tab portions of the positive electrode plates are stacked and electrically connected to form a backup positive electrode tab. The negative electrode plate has an extended third tab portion and fourth tab portion. The third tab portions of the negative electrode plates are stacked and electrically connected to form a main negative electrode tab, and the fourth tab portions of the negative electrode plates are stacked and electrically connected to form a backup negative electrode tab.