Tab Insulating Layer Thickness Variation for Short Circuit Prevention
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Solution Overview
Problem
Conventional energy storage device electrodes with insulating layers on tabs are prone to electrical contact due to lamination deviations, leading to potential short circuits, especially when the substrate is exposed on the side surfaces of the tabs.
Innovation Solution
An energy storage device electrode with a conductive substrate and an insulating layer coating both the surface and side surfaces of the tab, preventing electrical contact by ensuring the side surface coating is thicker than the surface coating, thereby preventing short circuits and maintaining performance during abnormal situations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating layer is provided only on the surface of the tab, then the manufacturing process is simple, but the side surface of the tab remains exposed and vulnerable to electrical contact during abnormal situations
Solution Approach 1:
The insulating layer is applied with different thicknesses at different locations: a first thickness on the surface and a greater second thickness on the side surface. This local variation in quality ensures that the side surface, which is exposed and vulnerable to electrical contact, receives enhanced insulation protection while the surface maintains sufficient insulation with less material.
2Reliability
If the insulating layer thickness is increased uniformly, then electrical contact prevention is improved, but material usage and manufacturing complexity increase
Solution Approach 1:
Instead of uniformly increasing the insulating layer thickness, the invention applies a greater thickness specifically to the side surface where electrical contact risk is highest, while maintaining a sufficient but not excessive thickness on the surface. This localized approach optimizes material usage by concentrating insulation material where it is most needed for safety.
3Ease of manufacture
If the tab structure remains conventional with exposed side surfaces, then manufacturing is straightforward, but deviation in lamination may cause electrical contact between electrodes
Solution Approach 1:
The insulating layer is applied to the tab before the tab is inserted into the electrode assembly, specifically coating the side surface with a greater thickness. This preliminary protective action ensures that even if lamination deviation occurs during assembly, the exposed side surface is already protected by the enhanced insulating layer, preventing electrical contact between electrodes.
Data Source
AI summary
One aspect of the present invention is directed to an energy storage device electrode including a conductive electrode substrate including a main body and at least one plate-shaped tab and an insulating layer coating a surface and a side surface of a base end of the tab.