Cylindrical Battery Sub-Tab Layout to Eliminate Tab Kneading
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Solution Overview
Problem
The existing tab kneading process in cylindrical lithium-ion battery manufacturing is prone to causing short circuits and safety issues due to the risk of tab deformation and metal debris generation, which affects the consistency and efficiency of the production process.
Innovation Solution
A cylindrical battery design where the tabs are formed by stacking and winding electrode plates with die-cutting lines to create sub-tabs, arranged in a staggered manner, eliminating the need for kneading and reducing the risk of tab shattering, with tabs led out from the same end and insulated to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tab kneading process is applied to flatten tabs before welding, then tabs can be properly positioned for welding, but tab deformation and metal debris generation occur causing short circuits and safety issues
Solution Approach 1:
The patent applies preliminary action by pre-forming die-cutting lines on the tabs during electrode plate manufacturing, so that tabs can be directly bent and flattened into sub-tabs without requiring subsequent kneading processing. This preliminary preparation eliminates the need for tab kneading while ensuring proper tab positioning and shape for welding, thereby preventing tab deformation and metal debris generation that cause short circuits.
2Quantity of substance
If tabs are bent and flattened in radial direction to form sub-tabs in staggered arrangement, then space utilization and energy density are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing each tab into multiple sub-tabs through die-cutting lines, creating a staggered arrangement where sub-tabs from adjacent tabs are offset from each other. This segmentation allows better space utilization within the battery cell, enabling higher energy density while the die-cutting process integrates smoothly into existing manufacturing equipment, minimizing the increase in manufacturing complexity.
3Manufacturing precision
If multiple die-cutting lines are applied to create sub-tabs, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent merges multiple die-cutting operations into a single integrated die-cutting process that creates multiple cutting lines on tabs simultaneously. This combined approach achieves high manufacturing precision with consistent tab shapes and proper staggered arrangement, while maintaining high production speed by eliminating the need for sequential cutting operations. The integrated process is fully automated and compatible with existing high-speed battery manufacturing lines.
Data Source
AI summary
Disclosed are a bare cell, a cylindrical battery and an assembly method of the bare cell. The bare cell is formed a cylinder by stacking and winding a first electrode plate, a separator and a second electrode plate, the polarity of the first electrode plate is opposite to the polarity of the second electrode plate, at least one of the first electrode plate and the second electrode plate forms a plurality of tabs at at least one end of the cylinder in an axial direction, each of the plurality of tabs is provided with at least one die-cutting line to form a plurality of sub-tabs, the plurality of tabs are bent and flattened in a radial direction, and the plurality of sub-tabs of two adjacent layers of the plurality of tabs are arranged in a staggered manner.