Secondary Battery Cap Assembly Insulation Groove
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Solution Overview
Problem
Cylindrical and prismatic secondary batteries face reduced life cycle and capacity due to limited inner space for electrolyte and electrode assembly, and a high probability of electrical short circuits caused by connected lead tabs and terminals, which can separate under external shocks.
Innovation Solution
A secondary battery design with a cap assembly that includes a coupling groove and insulation member allowing for a larger inner space, reducing the risk of electrical short circuits by separating lead tabs and terminals, and increasing the amount of electrolyte solution and electrode assembly size, while the insulation member is slidably connected to the cap plate, enhancing safety and reducing space occupancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the inner space of the case is increased to accommodate more electrolyte solution and larger electrode assembly, then the battery capacity and life cycle are improved, but the case size and complexity increase
Solution Approach 1:
The cap assembly is divided into multiple functional components: cap plate, insulation member, and sealing member. This segmentation allows each component to perform its specific function efficiently while optimizing the overall space utilization within the case.
Solution Approach 2:
The insulation member is positioned in a vertical arrangement within the cap assembly, utilizing the vertical dimension to separate electrical components. This dimensional arrangement allows for adequate insulation space without increasing the horizontal footprint of the battery.
2Reliability
If lead tabs and electrode terminals are separated to reduce electrical short circuit risk, then safety is improved, but the device complexity increases
Solution Approach 1:
An insulation member is introduced as an intermediary component between the lead tabs and electrode terminals. This insulation member physically separates the positive and negative terminals, preventing electrical short circuits while providing a simple and effective solution.
Solution Approach 2:
The insulation function is extracted as a separate component (insulation member) from the overall cap assembly structure. This allows the insulation function to be performed by a dedicated element, simplifying the design and reducing the complexity of integrating insulation into the terminal structure.
3Ease of manufacture
If the cap assembly structure is simplified to reduce manufacturing complexity, then ease of manufacture is improved, but the ability to separate terminals for safety is reduced
Solution Approach 1:
The cap plate, insulation member, and sealing member are combined into an integrated cap assembly that is installed as a single unit on the case. This merging simplifies the manufacturing process and assembly operations while maintaining the terminal separation function through the included insulation member.
Solution Approach 2:
The cap assembly is designed to perform multiple functions: sealing the case, providing electrical insulation between terminals, and facilitating terminal connections. By integrating these functions into a single assembly, the design achieves both manufacturing simplicity and safety requirements.
Data Source
AI summary
A secondary battery is disclosed. In one aspect, the secondary battery includes an electrode assembly, a case having an opening and housing the electrode assembly and a cap assembly sealing the opening of the case. The cap assembly includes an electrode terminal electrically connected to the electrode assembly. The cap assembly also includes a cap plate including a first terminal hole into which the electrode terminal is inserted and a coupling groove extending from a lateral surface of the cap plate past the first terminal hole. The coupling groove has an open side facing the electrode assembly. The cap assembly further includes an insulation member connected to the cap plate via the inside of the coupling groove and configured to be slidably engaged with the coupling groove.