Electrode Plate Tab Interlock for Fatigue-Resistant Battery Cells

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Solution Overview

Problem

Current electrode plate assemblies in battery cells face reliability issues due to mechanical fatigue at the junction between the tab and the electrode plate, caused by stress from electrode expansion, leading to connection failure.

Innovation Solution

An electrode plate assembly design featuring a tab with a bulge embedded in a recess on the electrode plate, increasing connection strength and contact area, thereby enhancing conductivity and reducing mechanical fatigue.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a planar tab and planar electrode plate surface are used, then the structure is simple and easy to manufacture, but the connection strength and conductivity are insufficient, leading to mechanical fatigue and connection failure

Engineering Contradiction:

Improveconnection reliabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies curvature by forming a bulge on the tab surface and a corresponding recess on the electrode plate surface. The bulge is then embedded into the recess to create a curved, interlocking connection interface. This curved geometry increases the contact area between tab and electrode plate, improving both connection strength and conductivity while reducing mechanical fatigue compared to planar surfaces.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent implements nesting by embedding the bulge formed on the tab into the recess formed on the electrode plate surface. The bulge fits within the recess, creating a nested, interlocking structure that mechanically bonds the tab to the electrode plate. This nested configuration enhances connection reliability by preventing relative movement and distributing stress more effectively.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If the contact area between tab and electrode plate is increased, then conductivity improves, but the manufacturing complexity increases

Engineering Contradiction:

ImproveconductivityVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The curved bulge and recess geometry naturally increases the contact area between tab and electrode plate compared to planar surfaces. The embossing and pressing processes that form these curved features can be integrated into existing manufacturing lines, achieving improved conductivity without proportionally increasing manufacturing complexity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS20250015451A1Electrode plate assembly, battery cell, and electrical device

Publication Date: 2025.01.09 NINGDE AMPEREX TECHNOLOGY LTD

AI summary

An electrode plate assembly includes an electrode plate and a tab. An electrode plate includes a first surface and a second surface that are disposed opposite to each other along a thickness direction of the electrode plate. The tab is disposed on the first surface and electrically connected to the electrode plate. A first bulge is disposed on the tab. A first recess is disposed on the first surface and recessed toward the second surface. The first recess does not penetrate the second surface. The first bulge is at least partially embedded into the first recess. The first bulge is at least partially embedded into the first recess to form a structure in which the electrode plate engages with the tab, thereby increasing connection strength between the tab and the electrode plate, and increasing tensile strength of the electrode plate assembly.