Elastic Tab Limiting Sheet for Battery Tab Short-Circuit Prevention
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Solution Overview
Problem
In lithium battery manufacturing, longer tabs are prone to deformation and reversal during usage, leading to internal short circuits, which can cause smoking, fires, and explosions due to machining limitations and environmental impacts.
Innovation Solution
A tab limiting sheet is designed with elastic elements and support parts to prevent contact between positive and negative pole tabs, absorbing deformation and maintaining a safe distance to prevent short circuits, and is integrated with a top cover assembly for stable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tabs are made longer to meet machining requirements, then manufacturing feasibility is improved, but tabs become prone to deformation and reversal during usage
Solution Approach 1:
The patent introduces a tab limiting sheet as an intermediary component between the tabs and the battery cell body. This limiting sheet includes limiting structures that physically constrain the tabs, preventing them from deforming or reversing position during battery usage. The intermediary structure allows the tabs to maintain their required length for manufacturing while providing mechanical constraints that ensure positional stability throughout the battery's operational life.
2Volume of moving object
If tabs are folded into a compact space, then battery packaging efficiency is improved, but tabs become susceptible to extrusion deformation and contact with opposite polarity pole pieces
Solution Approach 1:
The tab limiting sheet serves as a protective intermediary structure embedded in the battery cell body that provides mechanical constraints for the folded tabs. The limiting structures on the limiting sheet create physical barriers that prevent tabs from being extruded or deformed during battery assembly and usage, while maintaining the compact folded configuration necessary for efficient battery packaging.
Solution Approach 2:
The patent implements preventive measures by pre-installing the tab limiting sheet with limiting structures before tab deformation or short circuit issues can occur. These limiting structures are positioned in advance to constrain tab movement, providing mechanical protection against extrusion forces that may occur during battery assembly, handling, or usage, thereby preventing harmful deformation before it happens.
3Device complexity
If no tab limiting structure is used, then device complexity is reduced, but internal short circuits occur due to tab contact with opposite polarity pole pieces
Solution Approach 1:
The tab limiting sheet acts as a simple yet effective intermediary component that provides mechanical constraints for the tabs. Rather than complicating the tab structure itself or the pole piece design, the patent introduces this separate limiting structure that interfaces between the tabs and the battery cell body, providing a straightforward solution to prevent tab contact with opposite polarity pole pieces while maintaining overall structural simplicity.
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 tab limiting sheet effectively prevents short circuits and reverse insertion of tabs, enhancing battery safety and quality by absorbing deformation and maintaining a safe distance between tabs, thereby reducing the risk of internal short circuits and improving safety factors.
Implementation Method 1
an elastic element, wherein both ends of the elastic element are respectively connected with the first mounting part and the second mounting part; when the elastic element is in a natural state, the first supporting part and the second supporting part are spaced in the first direction, and when the elastic element is squeezed to a maximum deformation state, the first supporting part is tightly abutted against the second supporting part
Data Source
AI summary
A tab limiting sheet, a top cover assembly, and a battery are provided. The battery is insulated and disposed between a cell body and two tab bodies. The tab limiting sheet includes a first mounting part, a connecting assembly, and a second mounting part. The connecting assembly includes an elastic element and a first support element. Both ends of the elastic element are respectively connected with the first mounting part and the second mounting part. The first support element includes a first supporting part connected with the first mounting part and a second part connected with the second mounting part. When the elastic element is in a natural state, the first supporting part and the second supporting part are spaced in the first direction. When the elastic element is squeezed to a maximum deformation state, the first supporting part is tightly abutted against the second supporting part.