Wound Electrode Tab Geometry for Accurate Battery Tab Recognition
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Solution Overview
Problem
Conventional battery technologies face issues with tab breakage and recognition errors during the tab recognition step in the manufacturing process, where the detection mechanism struggles to differentiate between detection tabs and normal tabs due to width differences, leading to weakened detection tabs and recognition failures.
Innovation Solution
The battery design incorporates a detection tab with a specific width ratio at its base and normal tabs, where the width of the detection tab's base is greater than 1.5 times the width of the tab itself, and the normal tab width is greater than 1.2 times the detection tab width, ensuring the detection tab is strong and easily detectable, thus reducing tab breakage and recognition errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the width of the detection tab at distance L is made smaller to improve detection accuracy, then the detection mechanism can more easily distinguish the detection tab from normal tabs, but the detection tab becomes weaker and more prone to breakage
Solution Approach 1:
The detection tab is designed with non-uniform width along its length. Specifically, the width at the base (W3) is made significantly larger than the width at distance L (W1), creating a tapered profile. This local variation in geometry allows the tab to have different properties at different locations: the narrow section at distance L provides good detection contrast while the wide base provides structural strength and resistance to breakage.
2Strength
If the base of the detection tab is made larger to increase strength, then the detection tab becomes less prone to breakage, but the width at distance L increases making it harder to distinguish from normal tabs
Solution Approach 1:
The detection tab is effectively segmented into different functional zones along its length. The base portion (width W3) serves the structural function of providing strength and anchoring, while the upper portion at distance L (width W1) serves the detection function of providing optical contrast. This segmentation of function along the tab's length allows each zone to be optimized for its specific purpose without compromising the other.
3Measurement precision
If the width difference between detection tab and normal tab at distance L is increased to improve detection accuracy, then the detection mechanism can more reliably distinguish between tab types, but the detection tab becomes weaker
Solution Approach 1:
The detection tab employs local quality variation by having a narrow width W1 at the detection-critical location (distance L from base) while maintaining a wide base width W3. This creates a localized narrow section that provides high detection contrast against normal tabs, while the overall tab structure remains strong due to the wide base. The principle of making different parts of the same component have different properties is key to resolving this contradiction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the strength of the detection tab and improves recognition accuracy, preventing tab breakage and recognition failures, allowing for precise cutting and maintaining the desired shape of the wound electrode body.
Implementation Method 1
The two tab recognition sensors S1 and S2 are each provided for example with an output part for emitting laser light and a receiving part for receiving the laser light from the output part, located facing the output part on the other side of the tab.
Data Source
AI summary
A battery disclosed here is provided with a wound electrode body comprising a strip-shaped first electrode and a strip-shaped second electrode stacked with a strip-shaped separator in between and wound in a winding direction. The first electrode has a first tab and second tabs protruding in a protruding direction, and given W1 (mm) as the width of the first tab at a distance L (L=3 to 10 mm) in the protruding direction, W2 (mm) as the width of the second tabs at the distance L in the protruding direction, and W3 (mm) as the width of the base of the first tab, both of the following formulae are satisfied: (W3/W1)>1.5; (W2/W1)>1.2.