Electrode Tab Misalignment Structure for Short-Circuit Clearance
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Solution Overview
Problem
Batteries in new energy vehicles face challenges in reliability due to misalignment of tab plates, which cause interference with other components and increase the risk of short-circuiting, affecting the energy density and assembly efficiency.
Innovation Solution
The electrode assembly design includes a tab part with misalignment areas and saw-toothed structures to enhance connection reliability and reduce interference, utilizing the misalignment areas to increase connection length and minimize burr length, while incorporating a cutting blade assembly for precise cutting to control burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tab plates are stacked and connected to form the tab part, then the electrical connection area is increased, but misalignment between tab plates causes interference with other components and increases short-circuit risk
Solution Approach 1:
The patent introduces misalignment areas where tab plates are intentionally not fully overlapped, creating an asymmetric structure. This asymmetric design allows the tab part to have a smaller width at certain positions, reducing interference with surrounding components while maintaining electrical connection reliability through the connecting parts that do overlap.
Solution Approach 2:
The tab part is segmented into overlapping portions (for electrical connection) and misalignment portions (for reducing interference). This segmentation allows different functional zones within the tab part, where the misalignment portions reduce short-circuit risk by creating clearance from other components while overlapping portions maintain electrical connectivity.
2Ease of operation
If the width of the tab part is reduced to minimize interference, then the clearance for penetration is improved, but the connection length between tab part and active substance-coated part is decreased
Solution Approach 1:
The patent applies local quality by having different width characteristics at different positions of the tab part. The misalignment areas have reduced width to facilitate penetration and reduce interference, while the overlapping areas maintain sufficient width to ensure adequate connection length and electrical conductivity. This localized variation in width optimizes both penetration convenience and connection reliability.
3Reliability
If the tab part structure is optimized for reliability, then the assembly complexity increases, but the assembly efficiency is improved
Solution Approach 1:
The misalignment structure is pre-designed and pre-formed in the tab part before assembly. The misalignment areas and connecting parts are created during tab part fabrication, so that during battery assembly, the reduced width portions automatically provide the necessary clearance from other components. This preliminary structuring simplifies the assembly process while maintaining high reliability.
Data Source
AI summary
An electrode assembly comprises an active substance-coated part and a tab part. The tab part comprises a plurality of tab pieces, overlapping parts of the plurality of tab pieces forming an overlapping region, and misaligned parts of the plurality of tab pieces forming a misalignment region connected to the overlapping region. The misalignment region comprises a first connection part and a second connection part, the side of the first connection part in a first direction being connected to the active substance-coated part, and the second connection part being connected to the other side of the first connection part in the first direction. In a second direction, the end of the second connection part away from the overlapping region is closer to the overlapping region than the end of the first connection part away from the overlapping region.