Electrode Tab Insulation Structure for Higher Energy Density
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Solution Overview
Problem
Lithium-ion batteries face a challenge in optimizing the structure of the electrode assembly to increase energy density, which is essential for meeting the higher energy demands of advanced electrical devices.
Innovation Solution
The electrode assembly incorporates a first electrode plate with a current collector and an active material layer, featuring a groove that houses a tab and an insulation piece. The insulation piece provides double-layer isolation protection, reducing the need for additional insulation adhesive and minimizing coverage on the active material layer, thereby increasing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional insulation pieces are used to cover the groove and tab, then safety is ensured, but the coverage area on the active material layer increases, reducing energy density
Solution Approach 1:
The insulation piece is divided into two distinct parts: a first portion that covers the groove and a protruding portion that covers the tab. This segmentation allows each part to perform its specific insulation function independently, reducing the overall coverage area on the active material layer while maintaining safety.
Solution Approach 2:
The protruding portion is extracted from the traditional flat insulation piece design and extended to specifically cover the tab area. This extraction allows the insulation function to be provided where needed (at the tab) without requiring additional insulation adhesive on the opposite electrode plate, thereby reducing the coverage area on the active material layer.
2Reliability
If the insulation piece is made thicker to ensure adequate insulation, then safety is improved, but the thickness of the electrode assembly increases, reducing energy density
Solution Approach 1:
The insulation piece adopts local quality by having different thicknesses in different regions: the first portion has a certain thickness to cover the groove, while the protruding portion has a controlled thickness that does not exceed the available space. This allows adequate insulation where needed while minimizing the overall thickness increase of the electrode assembly.
Solution Approach 2:
The insulation solution transitions from a two-dimensional flat piece to a three-dimensional structure with a protruding portion. This dimensional change allows the insulation function to be provided in the vertical direction (covering the tab) without proportionally increasing the horizontal coverage area, thereby improving insulation performance while controlling the overall thickness.
3Reliability
If insulation adhesive is applied to the groove and opposite electrode plate, then insulation is ensured, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The first portion and protruding portion are merged into a single integrated insulation piece structure. This merging eliminates the need for separate insulation adhesive applications on both the groove and the opposite electrode plate, simplifying the manufacturing process while maintaining comprehensive insulation coverage.
Solution Approach 2:
The protruding portion of the insulation piece serves itself by extending to cover the tab area, eliminating the need for additional insulation adhesive on the opposite electrode plate. This self-service design reduces the number of manufacturing steps required while ensuring complete insulation.
Data Source
AI summary
An electrode assembly includes a first electrode plate, a first tab, and a first insulation piece. The first electrode plate includes a first current collector and a first active material layer that disposed on a surface of the first current collector. A part of the surface of the first current collector exposes the first active material layer to form a first groove. one end of the first tab is disposed in the first groove, and is electrically connected to the first current collector. The first insulation piece includes a first portion and a protruding portion. The first portion is fixed onto the first active material layer. The first portion covers the first groove. The protruding portion covers the first tab. Along a length direction of the first electrode plate, a width of the protruding portion is less than or equal to a width of the first groove.