Rechargeable Battery Cap Assembly Composite Insulation
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Solution Overview
Problem
There is a need for rechargeable batteries to achieve weight reduction, increased electrical capacity, and enhanced structural stability, particularly in small wearable devices where space and weight constraints are significant.
Innovation Solution
A rechargeable battery design featuring an electrode assembly with a cap assembly that includes a combination of metal and plastic layers, where the cap assembly includes a first metal layer contacting the second electrode tab, a second metal layer spaced from the first metal layer and contacting the case, and plastic portions that insulate and bond the metal layers, reducing weight while increasing structural stability and electrical capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery size is reduced for wearable devices, then the device becomes more portable and wearable, but the electrical capacity decreases
Solution Approach 1:
The cap assembly uses a composite structure combining metal layers (for electrical conductivity and structural strength) and plastic portions (for insulation and sealing). This allows optimal material selection for each functional requirement, maximizing space utilization and electrical capacity within the limited battery volume while maintaining structural integrity
Solution Approach 2:
The electrode assembly uses a wound configuration where electrodes are wrapped around a central axis, transforming a two-dimensional electrode surface into a three-dimensional cylindrical structure. This increases the effective electrode surface area and electrical capacity within the constrained battery volume, allowing more active material to be packed into the available space
2Volume of moving object
If the battery volume is minimized for wearable applications, then portability improves, but structural stability deteriorates
Solution Approach 1:
The cap assembly combines metal layers providing structural strength and rigidity with plastic portions providing insulation and sealing. This composite structure maintains structural stability and prevents short circuits between electrodes even in the minimized battery volume, as each material contributes its superior properties to the overall assembly
Solution Approach 2:
The cap assembly is divided into distinct functional segments: metal layers for electrical conduction and structural support, plastic portions for insulation and sealing, and specific geometric features like the reverse staircase form. This segmentation allows each component to be optimized for its specific function while working together to maintain overall structural stability in the compact battery design
Data Source
AI summary
A rechargeable battery includes: an electrode assembly including a first electrode, a second electrode, and a separator disposed between the first electrode and the second electrode; a case including an opening disposed in one side and receiving the electrode assembly; a cap assembly combined to the opening and closing and sealing the case; a first electrode tab extending from the first electrode and combined to the case; and a second electrode tab extending from the second electrode and combined to the cap assembly, wherein the cap assembly includes a first metal layer contacting the second electrode tab, a second metal layer spaced from the first metal layer and contacting the case, and a first plastic portion insulating between the first metal layer and the second metal layer.