Notched Insulation Tape for Jelly Roll End Overlap Control
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Solution Overview
Problem
Existing secondary battery designs face issues with electrical connection defects due to overlapping insulation tape at the ends of electrode assemblies, leading to separation and reduced energy density.
Innovation Solution
An insulation tape with a notching pattern is used to minimize overlap at the ends of electrode assemblies, preventing separation and enhancing electrical connections, thereby increasing energy density and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation tape is used to cover both the lateral surface and end of the electrode assembly, then insulation coverage is improved, but overlapping at the end causes stepped portions that lead to separation between components
Solution Approach 1:
The insulation tape is divided into multiple segments along its length, with notched portions removed at intervals. This segmentation allows the tape to wrap around the electrode assembly end without overlapping, eliminating stepped portions while maintaining continuous insulation coverage on both the lateral surface and end surfaces.
Solution Approach 2:
Specific notched portions are extracted (removed) from the insulation tape at strategic locations. These removed sections prevent the tape from overlapping when wrapping around the electrode assembly end, thereby eliminating the stepped portions that cause component separation while preserving insulation functionality.
2Reliability
If insulation tape covers the end of the electrode assembly, then electrical insulation is improved, but overlapping creates spaces between the end of the electrode assembly and additional insulation members
Solution Approach 1:
The insulation tape is segmented with notched portions removed at regular intervals. This segmentation enables the tape to conform precisely to the electrode assembly end geometry without overlapping, eliminating gaps between the tape and additional insulation members, thereby improving positioning accuracy.
Solution Approach 2:
The insulation tape has varying properties along its length - continuous coverage on the lateral surface and segmented coverage at the end portions. This local quality variation allows the tape to provide insulation where needed while avoiding overlap and gaps at critical transition zones.
3Reliability
If insulation tape is applied to cover the electrode assembly, then protection is improved, but overlap at the end increases material usage and reduces energy density
Solution Approach 1:
Notched portions are extracted from the insulation tape to eliminate overlapping sections. This removal of redundant material reduces the total quantity of insulation tape required, thereby reducing material usage and increasing the energy density of the battery without compromising protection functionality.
Solution Approach 2:
The overlapping portions of insulation tape are discarded (removed via notching) as they provide redundant protection. This elimination of waste material optimizes the ratio of protective function to material consumption, improving energy density while maintaining adequate protection.
Data Source
AI summary
A jelly roll includes an electrode assembly made by winding a stack of a first electrode, a separator, and a second electrode, and an insulation tape configured to cover at least a part of a lateral surface of the electrode assembly and at least a part of an end of the electrode assembly, in which the insulation tape has at least one notching pattern provided in a region that covers at least a part of the end of the electrode assembly. The jelly roll can be used in a secondary battery, a battery module, and a battery pack.