Battery Cell Adapter Insulation for Thermal Runaway Isolation

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Solution Overview

Problem

Battery cells face safety issues due to thermal runaway and mechanical vibration, which can lead to short-circuiting and explosion, particularly at the fragile transitional connecting region of the adapter component.

Innovation Solution

Incorporating an insulation piece to cover at least part of the transitional connecting region of the adapter component, which is designed to heat up faster and break easily to cut off the current flow path, while providing protection against mechanical vibration and enhancing the safety performance of the battery cell.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the transitional connecting region is made fragile to break easily during thermal runaway, then safety performance is improved, but the region becomes more susceptible to damage from mechanical vibration

Engineering Contradiction:

Improvesafety performanceVSAvoidmechanical strength of transitional connecting region

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The adapter component is divided into distinct regions: a first connecting region, a transitional connecting region, and a second connecting region. The transitional connecting region is specifically designed with different material properties (higher aluminum content) to make it the weakest link that breaks first during thermal runaway, isolating the hazard while maintaining structural integrity in other regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the adapter component have different material compositions. The transitional connecting region contains more aluminum (9-11 mass%) compared to the first and second connecting regions (6-8 mass% aluminum), creating localized variations in melting point and strength to achieve selective breaking during thermal events.

Inventive Principle:

Principle #3Local quality

2Reliability

If the transitional connecting region is designed to heat up faster during overcurrent, then safety performance is improved, but the region becomes more vulnerable to thermal damage during normal operation

Engineering Contradiction:

Improvesafety performanceVSAvoidthermal sensitivity of transitional connecting region

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The material composition parameter (aluminum content) is specifically adjusted in the transitional connecting region to 9-11 mass%, higher than the first and second connecting regions. This parameter change lowers the melting point and increases thermal conductivity in the transitional region, enabling it to heat up faster and break first during overcurrent or thermal runaway events.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of moving object

If the adapter component is made robust to withstand vibration, then service life is improved, but the ability to break easily during thermal runaway is reduced

Engineering Contradiction:

Improveservice life of adapter componentVSAvoidsafety performance

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The adapter component is segmented into regions with different mechanical properties. The transitional connecting region is designed as the sacrificial element with lower strength, while the first and second connecting regions maintain higher strength for structural support and vibration resistance during normal operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The potential vulnerability of the transitional connecting region is converted into a safety feature. Its lower strength and higher thermal sensitivity, which could be seen as weaknesses, are actually beneficial as they enable the adapter to break in a controlled manner during thermal runaway, preventing catastrophic failure of the entire battery system.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

The insulation piece improves the service life and safety performance of the battery cell by preventing short-circuiting and explosion, ensuring the transitional connecting region melts and breaks off quickly to prevent overcurrent-related incidents.

Implementation Method 1

an insulation piece, covering at least a part of the transitional connecting region... because the transitional connecting region is covered by the insulation piece, the transitional connecting region heats up faster than the first connecting region and the second connecting region

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12519183B2Battery cell, battery, and electrical device

Publication Date: 2026.01.06 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

A battery cell includes: an end cap assembly, including an electrode terminal; a housing, on which an opening is created, where the end cap assembly seals the opening; an electrode assembly, disposed in the housing, where the electrode assembly includes a tab; an adapter component, connected between the tab and the electrode terminal, where the adapter component includes a first connecting region configured to be connected to the electrode terminal, a second connecting region configured to be connected to the tab, and a transitional connecting region located between the first connecting region and the second connecting region; and an insulation piece, covering at least a part of the transitional connecting region.