Electrode Tab Insulator Coating Passage for Uniform Battery Isolation
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Solution Overview
Problem
Rechargeable batteries face safety issues due to potential short-circuiting between positive and negative electrode tabs, which can lead to ignition, particularly during heat exposure.
Innovation Solution
A device for coating an electrode tab insulator is designed with a top die, bottom die, and shim member to uniformly apply an insulator on the electrode tab, forming a passage with specific angles and tapers to enhance insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional coating method is used without a controlled passage, then the coating process is simple, but the insulator coating is non-uniform leading to potential short-circuits
Solution Approach 1:
The coating device is segmented into distinct functional components: a top die with inlet, a bottom die, and a shim member with a controlled passage. This segmentation allows each component to perform its specific function - the passage controls insulator flow while the dies provide structural support and coating surfaces, achieving uniform coating without excessive overall complexity
Solution Approach 2:
The shim member acts as an intermediary component between the top and bottom dies. It introduces a controlled passage that mediates the flow of insulator material, ensuring uniform distribution across the electrode tab while maintaining a relatively simple overall device structure through this single intermediate element
2Reliability
If the insulator coating is non-uniform, then the device structure is simple, but short-circuits occur between electrode tabs during heat exposure
Solution Approach 1:
The passage structure incorporates dynamic flow control through its multi-segmented design with first, second, and third via portions at different angles. This dynamic geometry adapts the insulator flow path to achieve uniform distribution across the tab width, enhancing reliability while keeping the passage as a single static component rather than a complex active system
Solution Approach 2:
The passage structure implements local quality variations through its multi-segmented geometry with different via portions oriented at different angles. Each segment provides localized flow control appropriate for its position, ensuring uniform insulator distribution across the entire tab width while maintaining overall structural simplicity
3Productivity
If the insulator is not uniformly coated on the electrode tab, then the coating process is faster, but heat exposure causes separator shrinkage and short-circuiting
Solution Approach 1:
The device performs preliminary action by uniformly coating the insulator on the electrode tab before heat exposure occurs. The controlled passage ensures proper insulator distribution in advance, preventing future short-circuit risks without requiring complex real-time monitoring or adjustment systems during operation
Solution Approach 2:
The insulator coating performs preliminary anti-action by creating a protective barrier on the electrode tab before heat exposure can cause separator shrinkage. This preventive coating, achieved through the simple yet effective passage structure, counteracts the harmful effects of heat exposure before they occur
Data Source
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AI summary
A device for coating an electrode tab insulator includes: a top die having an inlet configured to receive an insulator; a bottom die on a lower side of the top die and coupled to the top die; and a shim member having a thickness (t) between the top die and the bottom die and including an outlet connected to the inlet and establishing a passage in which the insulator flows in a width direction of the outlet.