Battery Electrode Tab Insulation Structure for Crack Prevention
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Solution Overview
Problem
Secondary batteries can experience cracks or ruptures at the edge of the electrode tab due to pressure applied by the electrode tab, which is not adequately addressed by existing technologies.
Innovation Solution
A secondary battery design that includes an insulation tape with step compensation units on the electrode uncoated portions, matching the thickness of the electrode tab, to distribute pressure evenly and prevent cracks or ruptures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrode tab is used to collect current from the electrode plate, then electrical conductivity is improved, but stress concentration causes cracks and ruptures at the tab boundary area
Solution Approach 1:
The patent applies different properties to different parts of the electrode structure. The electrode tab area receives localized reinforcement through the insulating tape with step compensation, while the rest of the electrode plate maintains its original properties. This localized quality change strengthens the vulnerable tab boundary area without affecting the overall electrical conductivity function.
Solution Approach 2:
The insulating tape with step compensation is applied in advance to the electrode uncoated portion before the battery assembly is completed. This pre-application creates a cushioning effect that prevents stress concentration and potential cracks from occurring during subsequent manufacturing processes or battery operation.
2Manufacturing precision
If pressure is applied to the electrode assembly during manufacturing, then assembly density is improved, but cracks occur along the electrode tab boundary area
Solution Approach 1:
The patent introduces a localized structural modification at the electrode tab boundary area through the insulating tape with step compensation. This localized quality enhancement provides targeted reinforcement where cracks are most likely to occur during pressure application, while allowing the rest of the assembly to achieve proper density.
Solution Approach 2:
The insulating tape acts as an intermediary element between the electrode plate and the external pressure during manufacturing. The step compensation design of the tape distributes the applied pressure more evenly, preventing stress concentration at the vulnerable electrode tab boundary area while still allowing sufficient pressure to achieve proper assembly density.
3Reliability
If the electrode tab thickness is increased to improve current collection, then electrical performance is improved, but pressure concentration increases causing more severe stress
Solution Approach 1:
Rather than uniformly increasing tab thickness throughout, the patent applies localized reinforcement through the insulating tape with step compensation at the electrode uncoated portion. This approach maintains the original tab thickness for optimal electrical performance while compensating for stress concentration at the critical boundary area through the additional tape layer.
Solution Approach 2:
The patent creates a composite structure by combining the electrode tab material with the insulating tape material. This composite construction at the tab boundary area provides both the electrical conductivity of the original tab and the mechanical reinforcement of the tape, distributing pressure more effectively without compromising current collection efficiency.
Data Source
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AI summary
A secondary battery includes: a first electrode plate including a first substrate having a first active material coated portion coated with a first active material and a first electrode uncoated portion not coated with the first active material; a second electrode plate including on a second substrate having a second active material coated portion coated with a second active material and a second electrode uncoated portion not coated with the second active material; a separator between the first electrode plate and the second electrode plate; an electrode tab connected to one of the first electrode uncoated portion and the second electrode uncoated portion; an insulation tape on the first electrode uncoated portion or the second electrode uncoated portion and covering the electrode tab; and a step compensation unit on a region of an upper surface of the insulation tape excluding a region corresponding to the electrode tab.