Battery Electrode Tab Insulation Layout for Easier Bending
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Solution Overview
Problem
Existing electrode plates in battery cells face challenges in reliability due to the risk of short circuits and self-discharging caused by the thickness of insulation layers on the tabs, which complicates the bending process and insertion into the electrode assembly.
Innovation Solution
The electrode plate design includes a current collector with first insulation layers on the tab surfaces, where the thickness ratio of the insulation layers to the tab part is limited to L≤1.3, facilitating easier bending and reducing the risk of short circuits by ensuring a smaller total thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of insulation layers on the tab is increased to prevent short circuits, then the reliability of the battery cell is improved, but the bending of the tab becomes more difficult and the total thickness increases
Solution Approach 1:
The patent applies different insulation layer thicknesses to different regions of the tab. The first insulation layer has a controlled thickness ratio L≤1.3 relative to the first part thickness, while the second insulation layer has a different thickness ratio M≤2.0 relative to the second part thickness. This local differentiation allows the tab to bend easily in the first region while maintaining sufficient insulation in the second region, resolving the contradiction between reliability and ease of operation.
Solution Approach 2:
The tab is divided into two distinct parts: a first part with a first insulation layer and a second part with a second insulation layer. Each part has different thickness requirements and insulation needs. By segmenting the tab structure, the patent enables differential insulation thickness optimization, allowing easy bending in one segment while maintaining reliability in another segment.
2Reliability
If the thickness of insulation layers is increased to reduce short circuit risk, then the reliability is improved, but the total thickness of the tab increases
Solution Approach 1:
The patent implements local quality by setting different thickness ratios for different regions. The first insulation layer thickness is controlled by ratio L≤1.3, while the second insulation layer thickness is controlled by ratio M≤2.0. This ensures that insulation is provided where needed without uniformly increasing the total thickness of the entire tab structure.
Solution Approach 2:
The patent applies partial insulation action by providing different insulation layer thicknesses in different regions rather than uniformly thick insulation across the entire tab. The first part has a thinner insulation layer (L≤1.3) while the second part has a thicker insulation layer (M≤2.0), optimizing the balance between reliability and total thickness.
3Reliability
If the thickness of insulation layers is increased to prevent short circuits, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The tab structure is segmented into two parts with different insulation characteristics. The first part has a first insulation layer with thickness ratio L≤1.3, and the second part has a second insulation layer with thickness ratio M≤2.0. This segmentation provides a clear, manageable structure that is easier to manufacture and control compared to a uniform thick insulation design.
Solution Approach 2:
The patent changes the insulation layer thickness parameter across different regions of the tab. By defining two different thickness ratios (L and M), the patent creates a parameter gradient that simplifies the manufacturing process while maintaining reliability, avoiding the need for complex multi-layer or variable-thickness structures.
Data Source
AI summary
An electrode plate, a preparation method therefor, a battery cell, a battery, and a power consuming apparatus. The electrode plate includes a current collector and first insulation layers. The current collector includes a main body part and a tab. The tab extends from a first end of the main body part. The first end is one end of the main body part along a first direction. The tab includes a first part and a second part. The first part is closer to the main body part than the second part. The first insulation layers are disposed on surfaces of two sides of the first part. A ratio L of a thickness of the first insulation layers to a thickness of the first part satisfies: L≤1.3.