Battery Cell Arrester Insulation Using Folded Separator Layers
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Solution Overview
Problem
Existing battery cell designs face challenges in insulating conductive traces from the housing due to their thin and delicate nature, making it difficult to achieve stable electrical connections and thermal management, particularly in prismatic cells.
Innovation Solution
A battery cell design where anode and cathode current collectors are bundled and insulated using converging folds of insulating layers, secured by a spring-like action from the cover pressure, eliminating the need for separate insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulation is applied to conductive traces, then electrical insulation from housing is achieved, but manufacturing complexity increases and reliability decreases due to thin and delicate traces
Solution Approach 1:
The patent combines the insulation function with the existing separator layers and housing structure. The separator layers serve dual purposes: separating electrode layers and providing insulation for conductive traces. The housing itself is designed to provide electrical insulation, eliminating the need for separate insulation components for the traces.
Solution Approach 2:
The separator layers are designed to perform multiple functions simultaneously: they separate adjacent electrode layers to prevent short circuits, provide electrical insulation for conductive traces, and maintain structural integrity. This multi-functionality reduces the need for additional dedicated insulation components.
2Strength
If conductive traces are made thicker to prevent wrinkling and tearing, then mechanical strength improves, but electrical conductivity and flexibility deteriorate
Solution Approach 1:
The patent applies different properties to different parts of the conductive trace system. The traces themselves remain thin to maintain flexibility and conductivity, while the separator layers and housing provide the necessary mechanical support and protection. This local differentiation allows each component to optimize its specific function without compromise.
3Ease of manufacture
If conductive traces are guided to eliminate separate insulation, then manufacturing simplicity improves, but insulation reliability may worsen due to trace delicacy
Solution Approach 1:
The separator layers are pre-positioned between electrode layers before assembly, creating built-in insulation pathways. The housing is designed with integrated insulation features that guide and protect conductive traces during assembly, eliminating the need for separate insulation steps while ensuring reliable electrical isolation.
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
Provides a simple and effective insulation method for conductive traces, ensuring stable electrical connections and improved thermal management, enhancing the lifespan and reliability of the battery cell.
Implementation Method 1
The insulating layers are held in position by a spring action of their respective folds against pressure exerted indirectly by the first cover
Data Source
Figure 1
Figure 1
AI summary
The invention describes a battery cell (1) comprising a layer stack (2) having a plurality of anode layers (An) and a corresponding plurality of cathode layers (K), wherein the anode layers (An) and the cathode layers (K) are stacked alternately on top of each other, and a separator layer (S) is arranged between each anode layer (An) and each cathode layer (K), and wherein at least at a first end face (F1) of the layer stack (2) anode and/or cathode discharge paths (4a, 4k) are led laterally out of the layer stack (2) from at least some of the anode layers (An) and/or some of the cathode layers (K). Furthermore, the battery cell (1) comprises a housing (26) which encloses the layer stack (2) with the anode and cathode discharge tracks (4a, 4k), and which has at least on the first end face (F1) of the layer stack (2) a first cover (8) with an internal anode current collector (12a) orcomprising an internal cathode current collector, wherein the anode current collectors (4a) and the cathode current collectors (4k) are each bundled together and contacted at the anode current collector (12a) and the cathode current collector, respectively, and at least two insulating layers (IL) which are attached at a first end (E1) to the top (Fo) and bottom (Fu) of the layer stack (2), respectively, wherein the insulating layers (IL) extend beyond the layer stack (2) with their free second ends (E2) and these second ends (E2) are aligned towards each other by forming folds (24) extending towards each other, such that the bundles (6a) of the anode current collectors (4a) and the cathode current collectors (4k) are connected to the anode current collector (12a) and the cathode current collector (4k), respectively.the cathode discharge paths are each carried between the two folds (24), and the insulating layers (IL) are held in position by a spring action of their respective folds (24) against a pressure which is exerted indirectly by the first cover (8).