Battery Cell Adapter Insulation for Vibration and Thermal Cutoff
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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 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, thereby preventing short-circuiting and improving safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transitional connecting region is exposed without insulation, then the adapter component maintains good electrical conductivity and ease of manufacture, but the transitional connecting region is prone to breakage due to mechanical vibration and can cause short-circuiting
Solution Approach 1:
An insulation piece is introduced as an intermediary component between the adapter component and the housing. This insulation piece covers the transitional connecting region, providing mechanical protection against vibration while maintaining electrical insulation. The intermediary element resolves the contradiction by adding protection without requiring fundamental changes to the adapter component's electrical function.
Solution Approach 2:
The adapter component is divided into distinct functional regions: the transitional connecting region, first connecting region, and second connecting region. By segmenting the structure and applying insulation specifically to the vulnerable transitional region, the design protects only where necessary, minimizing overall complexity while improving reliability at the critical point.
2Quantity of substance
If the transitional connecting region is made with smaller cross-sectional area to reduce material, then manufacturing cost decreases, but the region becomes more susceptible to breakage from vibration
Solution Approach 1:
The cross-sectional area parameter of the transitional connecting region is optimized to balance material usage and mechanical strength. By carefully selecting the dimensional parameters, the design achieves adequate strength with minimal material, then adds insulation to provide the remaining protection needed, resolving the contradiction between material efficiency and mechanical durability.
3Ease of manufacture
If the adapter component uses uniform cross-sectional area throughout, then manufacturing simplicity is maintained, but the transitional connecting region cannot heat up faster during thermal runaway events
Solution Approach 1:
Instead of uniform cross-sectional area throughout the adapter component, the transitional connecting region is designed with specific local characteristics that enable faster heating during thermal runaway. This local quality change allows the critical region to respond differently to thermal stress while maintaining overall manufacturing simplicity through standardized processes.
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 enhances the service life and safety performance of the battery cell by protecting the transitional connecting region from mechanical vibration and ensuring rapid disconnection during thermal runaway.
Implementation Method 1
the insulation piece covers at least a part of the transitional connecting region... the transitional connecting region can keep insulated from the electrode assembly or the end cap assembly when breaking off
Implementation Method 2
the insulation piece can provide protection for the transitional connecting region, increase the service life of the transitional connecting region, and alleviate the problem that the transitional connecting region is prone to be broken by vibration
Implementation Method 3
when the battery cell is overcharged or an overcurrent flows through the battery cell due to other abnormalities, 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
Implementation Method 4
the transitional connecting region can melt and break more easily to cut off the current flow path between the tab and the electrode terminal, thereby substantially preventing the battery cell from exploding due to overcurrent
Data Source
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, a transitional connecting region located between the first connecting region and the second connecting region, and an embossed region including a plurality of friction bulges; and an insulation piece, covering at least a part of the transitional connecting region. The first connecting region is located inside the embossed region.