Electrode Assembly Tab Layout to Prevent Coating Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The cutting of tabs in electrode plates of secondary batteries can cause the active material layer to fall off, leading to material waste and increased costs, and the risk of short circuits due to impurities and stress concentration during vibration and swelling.
Innovation Solution
The electrode assembly design includes transition regions on the current collectors where the active material layer is not applied, reducing the risk of material loss during tab cutting and stress concentration, and incorporates insulation layers to minimize impurities and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tabs are cut from the current collector to facilitate electrical connection, then electrical connection capability is improved, but the active material layer may fall off causing material waste
Solution Approach 1:
The current collector is divided into three distinct regions: a coated region with active material layer, a transition region without active material layer, and a tab region for electrical connection. This segmentation allows the tab to be cut from the uncoated region, preventing active material loss while maintaining electrical connectivity.
Solution Approach 2:
The transition region is designed in advance as an uncoated zone between the coated region and the tab. This preliminary preparation ensures that when the tab is later cut, the cutting tool acts only on the uncoated transition region, preventing damage to the active material layer and avoiding material waste.
2Reliability
If the transition region extends beyond the active material layer edge, then cutting safety is improved, but the risk of short circuits increases
Solution Approach 1:
The position and dimensions of the transition region are precisely controlled within specific parameter ranges. The transition region extends beyond the active material layer edge to ensure cutting safety, but its extension is limited to prevent excessive overlap that could cause short circuits, achieving an optimal balance between the two requirements.
3Reliability
If insulation layers are added to prevent short circuits, then electrical safety is improved, but manufacturing complexity increases
Solution Approach 1:
Insulation layers are applied selectively only in specific regions where short circuit risk exists, such as at the edges of the active material layer and in the transition region. This localized insulation approach provides necessary electrical safety while minimizing the amount of insulation material and reducing manufacturing complexity compared to complete coverage.
Data Source
AI summary
An electrode assembly and a battery cell is disclosed. The electrode assembly includes a first electrode plate and a second electrode plate. The first electrode plate includes a first current collector and a first active material layer, the first current collector includes a first main body and a first tab, and the first tab extends from one end of the first main body in a longitudinal direction. The second electrode plate includes a second current collector and a second active material layer, the second current collector includes a second main body and a second tab, the second tab extends from one end of the second main body in the longitudinal direction, and the second active material layer is applied on a surface of the second main body.