Battery Electrode Plate Tab Structure for Reliable Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Poor welding quality of battery tabs due to the presence of an insulating layer in the current collector, leading to reliability issues in battery performance.
Innovation Solution
The electrode plate design includes a conductive layer with a tab portion in a second region of reduced thickness, where the insulating layer has a thickness gradient, facilitating easier welding and reducing the risk of false welding by minimizing the thickness difference between regions, thereby improving the structural homogeneity and manufacturing efficiency of the current collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating layer is added to the current collector to prevent short circuits, then safety is improved, but welding quality deteriorates due to interference with electrical connection
Solution Approach 1:
The insulating layer is designed with varying thickness: a first thickness in the first region and a second thickness (smaller than the first) in the second region where the tab portion is located. This local differentiation allows the insulating layer to provide safety where needed while minimizing interference with welding quality at the tab portion, thus resolving the contradiction between safety and welding quality.
2Ease of manufacture
If the insulating layer has uniform thickness, then manufacturing simplicity is improved, but stress concentration occurs leading to reduced fatigue life
Solution Approach 1:
The insulating layer transitions from a uniform thickness design to a non-uniform thickness design, with a first thickness in the first region and a second (smaller) thickness in the second region. This local variation reduces stress concentration at critical areas, thereby improving fatigue life while maintaining reasonable manufacturing simplicity through the defined thickness gradient.
3Manufacturing precision
If the tab portion thickness is increased to improve welding stability, then welding quality is improved, but the overall current collector thickness increases affecting energy density
Solution Approach 1:
The current collector is designed with a tab portion having a third thickness that is greater than both the first and second thicknesses of the insulating layer. This localized thickness increase at the tab portion improves welding stability and quality without significantly increasing the overall current collector thickness, thereby minimizing the impact on energy density while achieving reliable welding.
Data Source
AI summary
An electrode plate includes a current collector. The current collector includes a conductive layer and an insulating layer. The conductive layer includes a tab portion. In thickness direction of the electrode plate, the conductive layer is provided at two opposite sides of the insulating layer. The insulating layer includes a first region and a second region, and in width direction of the electrode plate, at least one end of the first region is connected to the second region. Thickness of the second region is less than thickness of the first region, and the tab portion is at least partially disposed in the second region. The electrode plate further includes an active substance layer applied on a surface of the conductive layer facing away from the insulating layer. The tab portion is not coated with the active substance layer.