Battery Electrode Assembly Insulation Against Case Short Circuits

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Solution Overview

Problem

Secondary batteries can experience internal short circuits due to contact between the electrode assembly and the metal case, leading to corrosion of the electrode plates.

Innovation Solution

Incorporating insulating portions on the surfaces of the electrode assembly, including an insulating material or film on the outer electrode portions and, in some cases, an auxiliary insulating portion on the inner surfaces of the case, to prevent contact between the electrode assembly and the case.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electrode assembly is placed directly in contact with the metal case, then the structural simplicity is maintained, but internal short circuits and corrosion occur

Engineering Contradiction:

Improveprevention of internal short circuitVSAvoidstructure of electrode assembly

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An insulating portion is introduced as an intermediary element between the electrode assembly and the metal case. This insulating portion prevents direct contact and potential short circuits while maintaining the overall structural integrity of the battery assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The electrode assembly is segmented into multiple components including a center electrode portion, outer electrode portions, and insulating portions. This segmentation allows for better control of electrical isolation and structural organization within the battery.

Inventive Principle:

Principle #1Segmentation

2Reliability

If insulating portions are added to the electrode assembly, then electrical insulation is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveelectrical insulationVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulating portion is merged with the outer electrode portions to form an integrated structure. This combination simplifies the manufacturing process by reducing the number of separate assembly steps while still providing effective electrical insulation between the electrode assembly and the metal case.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the outer electrode portion is made larger to provide better insulation, then the insulation effectiveness is improved, but the battery volume increases

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidbattery volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The insulating properties are applied locally at critical areas where electrical contact between the electrode assembly and metal case is most likely to occur. This targeted approach provides effective insulation without unnecessarily increasing the overall battery volume.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP4679548A1Secondary battery and method of manufacturing the same

Publication Date: 2026.01.14 SAMSUNG SDI CO LTD

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AI summary

A secondary battery may include an electrode assembly including a first electrode, a second electrode, and a separator, a case accommodating the electrode assembly, and an insulating portion on an upper surface and a lower surface of the electrode assembly, the insulating portion insulating the case and the electrode assembly from each other.