Electrode Tab Insulation Layer for Short-Safe Battery Cell Assembly
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Solution Overview
Problem
The thin tabs in electrode assemblies of secondary batteries are prone to being pressed between the electrode plates, leading to short-circuit risks during assembly, which compromises safety and energy density.
Innovation Solution
An insulation layer with a lower elastic modulus than the tab is coated on the tab surfaces, ensuring separation and reducing short-circuit risks while allowing for easy bending and minimizing space occupation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the tab is made thin to reduce space occupation, then the energy density is improved, but the tab is easily pressed between electrode plates causing short-circuit risk
Solution Approach 1:
An insulation layer is introduced as an intermediary between the tab and the electrode plates. This insulation layer prevents direct contact between the conductive tab and the electrode plates, eliminating the short-circuit risk while allowing the tab to remain thin for high energy density. The insulation layer acts as a mediator that resolves the conflict between electrical conductivity and insulation requirements.
Solution Approach 2:
The insulation layer is designed as a thin film structure that covers the tab surface. This thin film provides the necessary insulation properties while minimizing the additional space occupied, thus maintaining high energy density. The flexible nature of the thin film allows it to conform to the tab geometry and withstand assembly pressures without causing short circuits.
2Reliability
If the insulation layer has high elastic modulus to provide strong insulation, then the short-circuit prevention is improved, but the tab bending capability is reduced
Solution Approach 1:
The elastic modulus of the insulation layer is optimized to a specific range that balances insulation performance and flexibility. By controlling the material composition and structure parameters, the insulation layer achieves sufficient mechanical strength to prevent short circuits while maintaining enough flexibility to allow tab bending during assembly and operation. This parameter optimization resolves the contradiction between rigidity and flexibility requirements.
Data Source
AI summary
This application provides an electrode assembly and a battery cell. The battery cell includes an electrode assembly, a housing, and a first electrode terminal. The housing includes an accommodation cavity. The electrode assembly is accommodated in the accommodation cavity, and the first electrode terminal is disposed in the housing. The electrode assembly includes a first electrode plate, a second electrode plate, and a separator. The separator separates the first electrode plate from the second electrode plate. The first electrode plate includes a first current collector, a first active material layer, and an insulation layer. The first current collector includes a first body portion and a first tab extending from the first body portion.