Wound Electrode Tab Layout for Magnetic Interference Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing secondary batteries face challenges in improving reliability due to issues such as magnetic field interference and short circuits caused by burrs on electrode plates.
Innovation Solution
The secondary battery design includes an electrode assembly with a first and second electrode plate, separated by a separator, and connected via tabs. The design ensures that the distance between the winding start ends and the tabs (L1/L2) is within a specific ratio to counteract magnetic fields and uses insulation layers to cover blank foil regions and tabs, reducing the likelihood of burrs causing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode plate structure is simplified without insulation layers, then manufacturing complexity is reduced, but the reliability decreases due to burrs penetrating the separator and causing short circuits
Solution Approach 1:
An insulation layer is introduced as an intermediary component between the electrode plate and the separator. This insulation layer acts as a mediator that prevents direct contact between burrs on the electrode plate and the separator, thereby eliminating the harmful effect of burrs without modifying the electrode plate structure itself. The insulation layer serves as a protective barrier that resolves the reliability issue while maintaining manufacturing simplicity.
Solution Approach 2:
The insulation layer is applied in advance to the electrode plate before assembly, providing preemptive protection against burr penetration. By preparing the insulation layer beforehand on the electrode plate surface, the design prevents potential short circuit issues before they can occur during battery operation, thus enhancing reliability without adding complex operational mechanisms.
2Object-affected harmful factors
If the distance ratio L1/L2 is adjusted to counteract magnetic fields, then magnetic field interference is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The design utilizes parameter adjustment by controlling the distance ratio L1/L2 between the winding start end and the tab on positive and negative electrode plates. By optimizing this geometric parameter within a specific range (0.8≤L1/L2≤1.2), the magnetic fields generated by both electrode plates are made substantially equal, causing them to counteract each other and reduce magnetic field interference. This approach transforms a physical problem into a controllable geometric parameter optimization.
3Reliability
If insulation layers are added to cover blank foil regions and tabs, then the probability of short circuits is reduced, but the device complexity and manufacturing steps increase
Solution Approach 1:
The insulation layer serves multiple functions simultaneously: it insulates the blank foil region, covers the tab, prevents burr penetration, and provides electrical isolation. By using a single component (the insulation layer) to fulfill multiple protective and insulating functions, the design achieves comprehensive short circuit prevention without proportionally increasing manufacturing complexity. The multi-functionality of the insulation layer makes the additional manufacturing step highly efficient.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly enhances the reliability of secondary batteries by minimizing magnetic field interference and reducing the probability of short circuits, thereby improving the stability and performance of the battery.
Implementation Method 1
a magnetic field generated on the first electrode plate can substantially counteract the magnetic field generated on the second electrode plate, thereby reducing the impact caused by the magnetic field generated by the secondary battery onto the electrical device
Data Source
AI summary
A secondary battery includes an electrode assembly. Along a winding direction of the electrode assembly, a distance between a first winding start end of a first electrode plate and a first tab is L1, and a distance between a second winding start end of a second electrode plate and a second tab is L2, satisfying: 0.8≤L1/L2≤1.2. The first electrode plate includes a first blank foil region. The first blank foil region is a winding end section of the first electrode plate. The second electrode plate includes a second blank foil region. The second blank foil region is a winding end section of the second electrode plate. The first tab is connected to the first blank foil region, and the second tab is connected to the second blank foil region. A first insulation layer is provided on the first blank foil region.