Secondary Battery Cap Assembly Insulation Plate Gap
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Solution Overview
Problem
Conventional secondary battery cap assemblies often result in gasket burning during the welding process due to heat generation, leading to potential explosions and internal heat issues from short-circuiting, especially in compact designs where precise alignment is challenging.
Innovation Solution
Incorporating an insulation plate and a gasket made of insulating material positioned below the cap plate, with a terminal groove and plate portion of circular or rounded shape, to create a gap between the welding area and the gasket, preventing direct heat exposure and allowing for controlled short-circuiting to reduce heat generation and explosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cap plate is welded to the can, then the battery structure is sealed and secure, but the gasket may be burned by welding heat
Solution Approach 1:
The invention divides the sealing structure into distinct segments: the gasket is separated from the welding area by positioning it within the terminal groove, while the insulation plate is positioned between the gasket and the cap plate welding surface. This segmentation isolates the gasket from direct exposure to welding heat while maintaining the sealing function.
Solution Approach 2:
The insulation plate serves as an intermediary element between the cap plate welding area and the gasket. It blocks and redirects welding heat away from the gasket, preventing burning while allowing the welding process to proceed normally. The terminal groove also acts as an intermediary structure that positions the gasket away from the direct heat path.
2Quantity of substance
If the battery is compressed, then energy density increases, but short-circuiting may occur causing internal heat generation and explosion
Solution Approach 1:
The insulation plate is positioned in advance between the cap plate and the gasket/electrode terminal assembly. This pre-positioned insulation cushion prevents direct contact and potential short-circuiting that could occur during compression, thereby maintaining reliability while allowing higher energy density.
Solution Approach 2:
The insulation plate acts as a mediator that prevents direct electrical contact between the cap plate (connected to one electrode) and the electrode terminal (connected to the other electrode). This intermediary barrier eliminates the short-circuit pathway while allowing mechanical compression to increase energy density.
3Volume of moving object
If compact design is implemented, then battery size is reduced, but precise alignment during welding becomes challenging
Solution Approach 1:
The terminal groove is designed with a circular cross-section, and the gasket is positioned within this curved geometry. This curved structure provides natural alignment features that guide the gasket and insulation plate into correct positions, reducing the need for high-precision alignment during welding even in compact designs.
Solution Approach 2:
The compact design is achieved through segmentation of functional zones: the terminal groove area for electrical connection, the insulation plate area for thermal and electrical isolation, and the welding area on the cap plate. This functional segmentation allows each zone to be optimized independently, maintaining manufacturing precision while reducing overall battery size.
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
Prevents gasket burning during welding, maintains the battery's appearance, and reduces internal heat and explosion risks by ensuring controlled short-circuiting between the cap plate and electrode terminal, enhancing safety and reliability in compact battery designs.
Implementation Method 1
a cap assembly for a secondary battery including a cap plate, an electrode terminal, a gasket and an insulation plate... a terminal groove, the gasket plate of the gasket and the plate portion of the electrode terminal... to create a gap between the welding area and the gasket, preventing direct heat exposure
Implementation Method 2
The gasket and the insulation plate may be made of the same insulating material... to reduce internal heat generation and prevent, e.g., explosion, etc. by short-circuiting a can and an electrode terminal quickly
Data Source
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AI summary
Abstract of the Disclosure According to the present invention there is provided a secondary battery comprising an electrode assembly; a can housing the electrode assembly; and a cap assembly on the can. The cap assembly includes: a cap plate including a terminal groove and a terminal hole placed inside the terminal groove; a gasket including a gasket post, a gasket plate and a center hole; the a gasket post being seated in the terminal hole and the gasket plate being disposed in the terminal groove; and an electrode terminal including a terminal post seated in the center hole of the gasket and a plate portion disposed on the gasket plate, wherein a gap is provided between the side walls of the terminal groove and the plate portion of the electrode terminal.