Electrode Sheet Tab Notch Layout for Crack-Resistant Transport
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Solution Overview
Problem
During the transportation of electrode sheets for electrochemical cells, tensile forces can cause stress concentrations at tab notches, leading to cracks, tears, or fractures, which compromises the integrity of the sheets and the reliability of the electrochemical cell production process.
Innovation Solution
The method involves cutting auxiliary notches transverse to the tab notches on the electrode sheet, distributing stress over a larger surface area to mitigate concentration at tab notch departure points, thereby reducing the likelihood of fractures and tears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tabs are cut on electrode sheets to enable folding and electrical pole definition, then the electrode sheets can be properly formed for electrochemical cell assembly, but stress concentrations occur at the tab notch departure points causing cracks, tears, or fractures during transport
Solution Approach 1:
The invention divides the tab structure into multiple segments by introducing auxiliary notches that create intermediate folding points. Instead of a single continuous tab, the tab is segmented into multiple sections that can fold independently, distributing the bending stress across multiple smaller regions rather than concentrating it at the main notch departure point.
Solution Approach 2:
The invention modifies the local geometry at the tab notch departure points by adding auxiliary notches that create rounded transition zones. This local geometric modification redistributes the stress field in the critical region, preventing stress concentration that would otherwise lead to cracks and fractures during transport and folding operations.
2Productivity
If electrode sheets are transported on transport rollers and return rollers, then the sheets can be moved to the winding station for assembly, but tensile forces during transport create stress concentrations that trigger fractures at tab notches
Solution Approach 1:
The auxiliary notches are cut into the electrode sheet before transport, pre-configuring the stress distribution pattern in advance. This preliminary structural modification ensures that when tensile forces are applied during subsequent transport operations, the stress is already distributed favorably across the tab region, preventing fractures before they can occur.
Solution Approach 2:
The auxiliary notches act as preemptive stress-relief features that cushion against the harmful effects of tensile forces during transport. By providing alternative stress pathways through the auxiliary notch geometry, the structure is pre-prepared to absorb and distribute transport-induced stresses, preventing them from concentrating at critical points.
Data Source
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AI summary
A method for forming an electrode for electrochemical cells comprises arranging an electrode sheet (11) having a thickness, a length (L) and a height (H), wherein the length (L) is measured along a longitudinal direction, the height (H) is measured along a transverse direction and the thickness is measured along a direction perpendicular to the longitudinal direction and the transverse direction, the electrode sheet (11) having a longitudinal free edge (12a); cutting a plurality of tab notches (19) on the electrode sheet (11) in a first portion (15) of the electrode sheet (11) extending transversely from the free edge (12a), wherein each tab notch (11) extends from a transversely outer end (19b) to a transversely inner end (19a); cutting a plurality of auxiliary notches (20) on the electrode sheet (11) in the first portion (15) of the electrode sheet (11), wherein each auxiliary notch (20) extends in a longitudinal direction and contacts a single tab notch (19) between the transversely outer end (19b) and the transversely inner end (19a) of the tab notch (19).