Wound Electrode Tab Insulation for Short-Circuit Prevention

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Solution Overview

Problem

Electrochemical apparatuses face reliability issues due to potential short circuits caused by contact between the tab and the housing, leading to reduced service life.

Innovation Solution

An electrochemical apparatus with a wound structure featuring an insulating sleeve that isolates the connection regions of the electrode plates from the housing, using an integrally connected insulating sleeve to prevent short circuits and reduce mechanical damage, while maintaining energy density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the electrode assembly is allowed to move within the housing during mechanical abuse, then the electrochemical apparatus can accommodate manufacturing tolerances and assembly variations, but the tab may contact the housing causing short circuits and reducing reliability

Engineering Contradiction:

Improveaccommodation of manufacturing tolerancesVSAvoidrisk of short circuit

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

An insulating sleeve is introduced as an intermediary component between the tab connection region and the housing. The sleeve includes a first region covering the connection region and a second region filling the space between the tab and housing, preventing direct contact while allowing controlled movement. This mediator structure resolves the contradiction by enabling tolerance accommodation without compromising safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating sleeve is pre-installed on the tab connection region before final assembly, creating a preliminary protective barrier. The second region of the sleeve is designed to fill the gap between the tab and housing in advance, preventing potential short circuits before they can occur during mechanical abuse or normal operation.

Inventive Principle:

Principle #9Preliminary anti-action

2Reliability

If an insulating sleeve is added to cover the connection region and fill the space between the tab and housing, then reliability is improved by preventing short circuits and mechanical damage, but the device complexity increases

Engineering Contradiction:

Improveprotection against short circuit and mechanical damageVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating sleeve merges two previously separate protective functions into a single integrated component: (1) covering the connection region to prevent short circuits, and (2) filling the space between the tab and housing to prevent mechanical damage. This consolidation reduces the number of separate parts while maintaining comprehensive protection, thereby improving reliability without proportionally increasing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating sleeve is designed as a multi-functional component that simultaneously provides electrical insulation, mechanical protection, and spatial positioning functions. The first region provides electrical isolation while the second region provides mechanical cushioning and positioning, allowing a single component to address multiple reliability concerns without requiring separate dedicated parts for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the insulating sleeve is made wider to fully cover the connection region, then protection effectiveness is improved, but the energy density of the electrochemical apparatus decreases

Engineering Contradiction:

Improveprotection effectivenessVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The insulating sleeve is designed with varying coverage dimensions at different locations: the first region covers only the critical connection region where short circuits are most likely to occur, while the second region extends to fill the space between the tab and housing. This localized protection approach provides maximum safety where needed while minimizing the overall volume occupied by the insulating material, thereby preserving energy density.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20260011751A1Electrochemical apparatus and electronic apparatus

Publication Date: 2026.01.08 NINGDE AMPEREX TECHNOLOGY LTD

AI summary

An electrochemical apparatus includes a housing, an electrode assembly, and an insulating sleeve. The electrode assembly is a wound structure, where a first electrode plate of the electrode assembly includes a current collector and a tab. The current collector includes a first side and a second side oppositely disposed in a first direction. The tab includes a first connection region connected to the first side and a second connection region connected to the first connection region. The electrode assembly includes a first end face and a second end face oppositely disposed in the first direction, where the second connection region forms the first end face. The insulating sleeve includes a first region and a second region integrally connected. The first region covers the first connection region, and the second region is disposed on the second connection region and has a first opening.