Electrode Tab Insulator Coating for Uniform Short-Circuit Protection
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Solution Overview
Problem
Rechargeable batteries face safety issues due to potential short-circuits between positive and negative electrode tabs, particularly during heat exposure, which can lead to ignition.
Innovation Solution
A device for coating an electrode tab insulator is designed with a top die, bottom die, and shim member to uniformly apply an insulator on the electrode tab, utilizing specific passage configurations to enhance insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulator is coated on the electrode tab to prevent short-circuits, then insulation safety is improved, but coating uniformity is difficult to achieve
Solution Approach 1:
The patent changes the geometric parameters of the passage, including setting specific angle ranges (θ1: 30°-60°, θ2: 60°-80°, θ3: 80°-100°) and width ratios (W1:W2:W3 = 3:2:1), to optimize the flow characteristics of the insulator material. These parameter adjustments ensure uniform coating distribution while maintaining insulation safety.
Solution Approach 2:
The patent introduces curved surfaces and rounded transitions in the passage design, replacing sharp angles with smooth curves. This prevents turbulence and dead zones in the insulator flow, ensuring uniform coating distribution across the electrode tab surface.
2Manufacturing precision
If the passage width is reduced to improve coating precision, then manufacturing precision is improved, but insulator flow becomes restricted
Solution Approach 1:
The patent transitions from a single-dimension narrow passage to a multi-dimensional graduated passage design with varying cross-sectional dimensions. The passage width progressively decreases (W1:W2:W3 = 3:2:1) while maintaining adequate height, allowing the insulator to flow smoothly through dimensional transitions rather than abrupt constrictions.
Solution Approach 2:
The patent creates a dynamic flow path where the passage dimensions change gradually along the flow direction. The angled walls (θ1, θ2, θ3) and tapered sections enable the insulator to adapt its flow pattern dynamically, maintaining productivity while achieving precise coating control at the outlet.
3Manufacturing precision
If the passage angles are increased to improve coating distribution, then manufacturing precision is improved, but passage volume increases
Solution Approach 1:
The patent divides the passage into multiple segmented sections with different angle characteristics. The first passage section has angle θ1 (30°-60°), the second has θ2 (60°-80°), and the third has θ3 (80°-100°). This segmentation allows optimized coating distribution in each zone while controlling overall volume through the width ratio W1:W2:W3 = 3:2:1.
Solution Approach 2:
The patent applies different angular characteristics to different local regions of the passage. Steeper angles (θ2, θ3) are applied where precise coating distribution is needed, while shallower angles are used in upstream sections. This local optimization achieves superior coating distribution without requiring excessive overall passage volume.
Data Source
AI summary
A device for coating an electrode tab insulator includes: a top die having an inlet configured to receive an insulator; a bottom die on a lower side of the top die and coupled to the top die; and a shim member having a thickness (t) between the top die and the bottom die and including an outlet connected to the inlet and establishing a passage in which the insulator flows in a width direction of the outlet.