Battery Cell Tab Layout With Insulator for Higher Energy Density
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Solution Overview
Problem
Current battery cell designs face challenges in maximizing energy density and ensuring safety due to the spatial constraints and risk of short circuits caused by the placement and deformation of electrode tabs.
Innovation Solution
The battery cell design incorporates an insulator between tabs of opposite polarities located on the same side of the body portion, restricting deformation and preventing contact, thereby increasing energy density and enhancing safety by isolating the tabs and reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If tabs of opposite polarities are located on the same side of the body portion to save space, then energy density is improved, but the risk of short circuit due to tab contact increases
Solution Approach 1:
An insulator is introduced as an intermediary component between the first tab and the second tab. The insulator prevents direct contact between tabs of opposite polarities while allowing both tabs to be located on the same side of the body portion, thus maintaining space efficiency while eliminating short circuit risk.
Solution Approach 2:
The insulator is positioned to segment the space between the first tab and the second tab, creating distinct isolated zones for each tab. This segmentation ensures that even though tabs are on the same side, they cannot contact each other, resolving the contradiction between space utilization and safety.
2Productivity
If the first tab is allowed to deform freely to increase flow area, then flow capacity is improved, but the risk of tab contact with the second tab increases
Solution Approach 1:
The insulator is pre-positioned between the first tab and the second tab before any deformation occurs. This preliminary protective measure counteracts the potential harmful effect of tab deformation, allowing the first tab to expand for better flow capacity while the insulator prevents it from contacting the second tab.
3Productivity
If more space is allocated to tabs to improve flow capacity, then productivity is improved, but the space available for the body portion decreases
Solution Approach 1:
Instead of increasing tab size in the radial direction (which would reduce body portion space), the insulator enables tabs to be positioned on the same side, utilizing the axial dimension more efficiently. This dimensional reorganization allows adequate tab flow area while preserving maximum space for the body portion, maintaining energy density.
Data Source
AI summary
A battery cell includes a housing, an end cap, an electrode assembly, and an insulator. An opening is created on the housing. The end cap is configured to fit and cover the opening. The electrode assembly is accommodated in the housing and includes a body portion, a first tab, and a second tab. The first tab and the second tab are of opposite polarities and located on a same side of the body portion. A least a part of the insulator is disposed between the first tab and the second tab and configured to restrict the first tab from deforming toward the second tab.