Electrode Plate Tab Slot Layout to Reduce Battery Short Circuits
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Solution Overview
Problem
The existing methods for preparing electrode plates often result in excess bare foil regions due to cutting inaccuracies, which affect the operational performance of batteries by damaging tab slots and increasing the risk of short circuits.
Innovation Solution
The electrode plate design includes a tab slot spaced apart from the edge, with a notch running through the current collector that has an arc-shaped surface between its inner wall faces, reducing stress and preventing burr formation, and an insulating film covering the tab slot and notch to enhance safety and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cutting mechanism is used to cut the electrode plate motherboard into electrode plates, then the electrode plates can be produced efficiently, but excess bare foil regions are formed due to cutting accuracy issues, affecting battery performance
Solution Approach 1:
The tab slot is pre-formed on the electrode plate motherboard at a position spaced away from the edge, before the cutting process. This preliminary positioning ensures that the tab slot is not damaged during subsequent cutting operations, eliminating the need for repositioning or repair while maintaining production efficiency and avoiding bare foil regions
Solution Approach 2:
The design proactively prevents the harmful effect of cutting inaccuracies by positioning the tab slot away from the edge, creating a buffer zone that protects the critical tab slot structure from potential damage during the cutting process, thereby preventing bare foil region formation before it can occur
2Volume of moving object
If the tab slot is positioned close to the edge of the electrode plate, then the battery structure is compact, but the tab slot is easily damaged during cutting, causing excess bare foil regions
Solution Approach 1:
The tab slot is positioned asymmetrically relative to the electrode plate edge, with a specific spacing distance maintained. This asymmetric positioning creates a protective buffer zone that shields the tab slot from cutting damage while preserving overall battery compactness through optimized space utilization
3Ease of manufacture
If the notch has sharp inner wall faces, then the manufacturing process is simple, but stress concentrates at the junction, causing burr formation and increasing short circuit risk
Solution Approach 1:
The notch inner wall faces are designed with arc-shaped surfaces instead of sharp angles, creating a curved transition at the junction. This curvature distributes stress evenly across the notch structure, preventing stress concentration and burr formation while maintaining manufacturing feasibility through standard forming processes
Data Source
AI summary
An electrode plate includes a current collector and membranes disposed on a surface of the current collector, where at least one of the membranes is provided with a tab slot, the tab slot is apart from an edge of the electrode plate along a width direction, and the tab slot exposes the surface of the current collector; the membrane provided with the tab slot is provided with a notch connecting to the tab slot on a side, where the notch runs through the current collector along a direction perpendicular to the membrane, and the notch has an arc-shaped surface. The risk of a short circuit in the electrode assembly having the electrode plate can be decreased and safety performance of the battery can be improved.