Battery Adhesion Fixation Insulator Dent for Overflow Control
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Solution Overview
Problem
The existing battery adhesion-fixation structures face issues with adhesive agent overflow reaching the electrode terminals, leading to potential faulty connections between the electrode terminals and terminal tabs due to the nonconductive nature of the adhesive agent.
Innovation Solution
Incorporating an insulator with a dent and optional sub-dent to accommodate overflowing adhesive agent, and a bus-bar module with through bores to direct and anchor the adhesive, preventing it from reaching the joining area between the electrode terminals and terminal tabs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive agent is used to fix battery cells onto a holder, then the fixation strength is improved, but the adhesive agent may overflow and reach the electrode terminal, causing faulty electrical connection
Solution Approach 1:
The insulator is segmented with multiple recesses (first recess and second recess) that are spatially separated to control adhesive flow in different zones. The first recess is positioned away from the electrode terminal to catch overflow, while the second recess is positioned near the terminal to provide additional containment, thus preventing adhesive from reaching the electrical connection area while maintaining fixation strength.
Solution Approach 2:
The insulator acts as an intermediary component between the adhesive agent and the electrode terminal. By introducing this intermediate structure with strategically positioned recesses, the adhesive overflow is intercepted and contained before it can reach the critical electrical connection area, thus protecting the reliability of the electrical connection while allowing the adhesive to perform its fixation function.
2Reliability
If the adhesive agent is applied in sufficient amount to ensure proper adhesion, then the bonding reliability is improved, but the risk of overflow reaching the electrode terminal increases
Solution Approach 1:
The insulator is pre-configured with first and second recesses before the adhesive application process. These recesses are positioned in advance to intercept and contain adhesive overflow as it occurs during the bonding process. This preliminary structural preparation allows sufficient adhesive to be applied for reliable bonding while the recesses are already in place to prevent harmful overflow from reaching the electrode terminal.
Solution Approach 2:
The adhesive overflow, which would normally be a harmful factor causing faulty electrical connections, is converted into a beneficial effect by directing it into the recesses of the insulator. The recesses capture the overflow adhesive, preventing it from reaching the electrode terminal, thus transforming the potential harm into a controlled feature that maintains bonding reliability while eliminating electrical connection risks.
3Reliability
If the insulator is positioned closer to the electrode terminal to better contain adhesive, then the protection against overflow is improved, but the risk of interfering with the electrical connection increases
Solution Approach 1:
The insulator exhibits local quality through its differentiated recess structure: the first recess is positioned away from the electrode terminal to provide general adhesive containment, while the second recess is positioned near the terminal with specific geometry to contain overflow without interfering with the electrical connection. This localized functional differentiation allows the insulator to provide superior adhesive containment while maintaining electrical connection integrity through the carefully positioned second recess.
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 solution effectively reduces adhesive agent overflow, enhancing the joining properties between the electrode terminals and terminal tabs, ensuring reliable electrical connections and improved fixation of battery cells.
Implementation Method 1
an adhesive agent adhering the battery cells with the holder within the holder holes
Implementation Method 2
the dent accommodating the adhesive agent overflown toward the insulator therein
Implementation Method 3
a terminal tab projecting into the bus-bar hole, the terminal tab to be electrically connected with the electrode terminal
Data Source
AI summary
A battery adhesion-fixation structure includes battery cells, a holder, an adhesive agent, bus bars, and an insulator. The holder includes holder holes for holding the battery cells therein. The adhesive agent adheres the battery cells with the holder within the holder holes. The bus bars electrically connect the battery cells with each other. The insulator intervenes between the bus bars and the holder. The bus bars include a bus-bar hole, and a terminal tab. The bus-bar hole faces face-to-face to an electrode terminal of the battery cells. The terminal tab projects into the bus-bar hole to be electrically connected with the electrode terminal. The insulator includes a face, and a dent opening in the face. The face opposes to the holder. The dent opens in the face, and accommodates the adhesive agent overflown toward the insulator therein.