Zinc Secondary Battery Tab Insulation to Prevent Separator Shorts
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Solution Overview
Problem
Zinc secondary batteries of the upward tab type are prone to short circuits due to insufficient welding of tab leads, which can cause peeling and subsequent penetration through hydroxide ion conductive separators or liquid holding members during charge/discharge cycles.
Innovation Solution
Attaching an insulating tape to the uncoated regions of the electrode plates to cover the weld-bonded portions of the tab leads, thereby preventing peeling and reducing the likelihood of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tab leads are weld-bonded to current collectors in uncoated regions, then electrical connection is achieved, but peeling occurs during charge/discharge cycles leading to short circuits
Solution Approach 1:
The insulating tape is attached to the uncoated region before the tab lead welding process. This preliminary action ensures that the tape is in place to prevent peeling during subsequent charge/discharge cycles, addressing the welding reliability issue before it occurs
Solution Approach 2:
The insulating tape acts as an intermediary material between the tab lead and the uncoated region of the current collector. It provides mechanical reinforcement to prevent peeling while maintaining electrical connectivity where needed, solving the bond strength problem
2Reliability
If insulating tape is attached to uncoated regions, then peeling is prevented, but manufacturing complexity increases
Solution Approach 1:
The insulating tape is applied only to specific uncoated regions where tab leads are welded, rather than covering the entire electrode plate. This segmented approach prevents short circuits in critical areas while minimizing additional manufacturing complexity and material usage
Data Source
AI summary
Provided is a zinc secondary battery including a positive electrode plate including a positive electrode active material layer and a positive electrode current collector; a positive electrode tab lead extending from an end of the positive electrode plate; a negative electrode plate including a negative electrode active material layer and a negative electrode current collector; a negative electrode tab lead extending from an end of the negative electrode plate; a hydroxide ion conductive separator; and an electrolytic solution. The electrode plates, the electrode tab leads, and the hydroxide ion conductive separator are vertically arranged respectively. The electrode plate has, along an upper end of the electrode plate, an uncoated region free from the electrode active material layer, and the electrode tab lead is weld-bonded to the current collector in the uncoated region, and an insulating tape is attached to the uncoated region to cover the weld-bonded portion.