Metal-Housing Secondary Battery Adhesion Layer for Short-Circuit Buffering
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Solution Overview
Problem
Lithium-ion batteries face safety concerns due to potential short-circuits caused by direct contact between the metal housing and electrode assembly during drops or collisions, leading to thermal runaway and fire, and existing insulating adhesives compromise energy density and increase production costs.
Innovation Solution
A secondary battery design featuring a metal housing with an adhesion layer on the bottom surface and inner side walls of the recess, which buffers the electrode assembly, reducing contact risks and using a controlled adhesive thickness and composition to enhance safety and energy density while minimizing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating adhesive is applied between the metal housing and the electrode assembly to prevent short-circuit, then safety performance is improved, but energy density decreases and production costs increase
Solution Approach 1:
The patent extracts the insulating function from the adhesive layer and assigns it to the housing structure itself through the recess design. The electrode assembly is positioned within the recess such that the housing structure provides the insulation barrier, eliminating the need for separate insulating adhesive layers and thereby increasing energy density while maintaining safety performance.
Solution Approach 2:
The housing structure is designed to serve multiple functions: structural support, electrode assembly positioning, and electrical insulation. The recess in the housing not only holds the electrode assembly but also provides the insulating barrier, making the housing a multi-functional component that eliminates the need for separate insulating materials.
2Reliability
If insulating adhesive is applied between the metal housing and the electrode assembly to prevent short-circuit, then safety performance is improved, but production costs increase
Solution Approach 1:
The insulating function is extracted from separate adhesive materials and integrated into the housing structure through the recess design. This eliminates the need for additional insulating adhesive materials and their associated application processes, thereby reducing production costs while maintaining the short-circuit prevention function.
Solution Approach 2:
The housing structure is designed to serve multiple functions including structural support, electrode assembly positioning, and electrical insulation. By making the housing multi-functional, the patent eliminates the need for separate insulating materials and their associated manufacturing steps, thereby reducing production costs.
3Reliability
If adhesive is applied to adhere the electrode assembly to the housing, then the electrode assembly is secured and tab connection failure is reduced, but the amount of adhesive required increases
Solution Approach 1:
The patent extracts the securing function from adhesive materials and implements it through the mechanical interfit between the electrode assembly and the housing recess. The electrode assembly is secured by its position within the recess structure rather than by adhesive bonding, thereby eliminating the need for large amounts of adhesive while maintaining tab connection reliability.
Solution Approach 2:
The recess structure provides a pre-designed mechanical constraint that secures the electrode assembly in place before any adhesive is applied. This beforehand positioning ensures that the electrode assembly is already stabilized and protected from movement that could cause tab connection failure, reducing the amount of adhesive needed for additional securing.
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 adhesion layer effectively reduces the risk of short-circuits and tab connection failures, improving safety performance and energy density while reducing production costs by eliminating the need for excessive adhesive, thus enhancing the overall performance of lithium-ion batteries.
Implementation Method 1
the adhesion layer adheres the electrode assembly to the housing
Data Source
AI summary
A secondary battery includes an electrode assembly, a housing, and an adhesion layer. The housing includes an upper housing body and a lower housing body. The lower housing body is provided with a recess for accommodating the electrode assembly. The upper housing body is configured to cover the recess. The adhesion layer is provided on a bottom surface of the recess opposite to the upper housing body. The housing is a metal housing. The adhesion layer adheres the electrode assembly to the housing.