Layer-Built Battery Tab for High-Current Heat Dissipation
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Solution Overview
Problem
Thick, single-piece metal tabs in high-current batteries face challenges in welding, bending, and heat dissipation, leading to overheating and performance issues.
Innovation Solution
A layer-built tab composed of stacked metal pieces connected by adhesives, enhancing heat dissipation and facilitating easy processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the thickness of the tab is increased to meet current-carrying requirements, then the current-carrying capacity is improved, but the difficulty of welding, bending, and other processes increases
Solution Approach 1:
The tab is divided into multiple thin metal sheets stacked together to form a layered structure. This segmentation allows each individual sheet to remain thin and easy to process, while the stacked combination achieves the required current-carrying capacity. The adhesive layers between sheets maintain structural integrity without requiring excessive thickness in any single component.
Solution Approach 2:
The tab employs a composite structure combining multiple metal sheets with adhesive materials. This composite approach enables the tab to achieve high current-carrying capacity through the stacked metal layers while the adhesives provide bonding and flexibility, making welding and bending processes easier compared to a single thick metal piece.
2Power
If the thickness of the tab is increased to meet current-carrying requirements, then the current-carrying capacity is improved, but heat dissipation performance deteriorates
Solution Approach 1:
By segmenting the tab into multiple thin metal sheets separated by adhesive layers, the structure creates internal pathways for heat dissipation. The adhesive layers act as thermal interfaces that facilitate heat transfer, and the stacked configuration increases surface area for heat dissipation compared to a solid thick tab of equivalent current capacity.
Solution Approach 2:
The composite structure of metal sheets combined with adhesive materials provides superior heat dissipation characteristics. The adhesives serve as thermal management materials that facilitate heat transfer between layers, while the stacked metal configuration increases overall surface area for heat dissipation, preventing overheating even at high current loads.
3Ease of manufacture
If a single solid tab is used, then the manufacturing process is simple and cost is low, but heat dissipation is insufficient leading to overheating
Solution Approach 1:
The tab is segmented into multiple thin metal sheets that can be individually processed and then stacked. This segmentation approach maintains manufacturing simplicity by using standard thin-gauge metal processing techniques, while the stacked configuration inherently provides improved heat dissipation through increased surface area and thermal pathways compared to a single solid tab.
Solution Approach 2:
The composite structure combining metal sheets with adhesive materials achieves both manufacturing simplicity and superior heat dissipation. The adhesives function as thermal management components that facilitate heat transfer, and the layered configuration provides excellent heat dissipation performance while remaining cost-effective and manufacturable.
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
Improves heat dissipation and processing ease, supporting high currents while reducing damage from high temperatures.
Implementation Method 1
a layer-built tab including adhesives and a plurality of metal pieces, the plurality of metal pieces are stacked together, and connected by the adhesives
Data Source
AI summary
The present application provides a layer-built tab, which includes a plurality of metal pieces and adhesives, the metal pieces being stacked and bonded by the adhesives. The metal pieces are stacked and spaced apart from each other, which increases the heat dissipation area of the tab while supporting a large current flow, the heat dissipation capability of the tab is improved. An electrode plate, a battery core, and a battery including the layer-built tab are also disclosed.