Secondary Battery Cap Plate Insulation for Simpler Assembly
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Solution Overview
Problem
Existing secondary batteries face challenges in insulation reliability and require complex assembly processes due to separate components for the cap plate and insulating parts, which can lead to inefficiencies and potential electrical faults.
Innovation Solution
Integration of a cap plate and insulating part to simplify the assembly process and enhance insulation reliability by using a modular design with a first and second insulator, coupled via a coupling part, and reinforced by a coupling reinforcement part to prevent movement and ensure electrical insulation between the cap plate and side terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cap plate and insulating part are provided as separate components, then the assembly process becomes complex and time-consuming, but the insulation reliability may be compromised due to potential assembly errors
Solution Approach 1:
The cap plate and insulating part are integrated into a single unified component. The insulating part is formed as an integral structure with the cap plate, eliminating the need for separate assembly steps while ensuring consistent insulation performance. This merging resolves the contradiction by simultaneously improving reliability through eliminated assembly errors and simplifying the device structure.
Solution Approach 2:
The integrated cap plate structure performs multiple functions simultaneously: it provides electrical connection functionality as a cap plate while also providing insulation functionality through the integrated insulating part. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly process while maintaining reliable insulation.
2Productivity
If the cap plate and insulating part are integrated into one component, then the assembly process is simplified and insulation reliability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The insulating part is pre-formed as an integral structure with the cap plate during the molding process. By preparing the integrated structure in advance through precision molding techniques, the patent enables simplified assembly operations while managing manufacturing complexity through advanced molding processes rather than complex post-assembly operations.
Solution Approach 2:
The patent replaces complex mechanical assembly operations with a unified molding process. Instead of requiring separate manufacturing and assembly steps for the cap plate and insulating part, the integrated structure is formed in a single molding operation, substituting mechanical assembly complexity with controlled manufacturing process complexity.
3Reliability
If separate insulators are used to insulate the cap plate from both the side terminal and electrode assembly, then insulation coverage is improved, but the number of components and assembly steps increases
Solution Approach 1:
The first insulator and second insulator are merged into a single integrated insulating structure formed as one piece with the cap plate. This unified insulating structure provides comprehensive insulation coverage for both the side terminal and electrode assembly interfaces without requiring separate insulator components, thereby maintaining full insulation coverage while reducing component count.
Solution Approach 2:
The integrated insulating structure performs multiple insulation functions simultaneously: it insulates the cap plate from the side terminal and also insulates the cap plate from the electrode assembly. This multi-functional insulating structure eliminates the need for separate insulators while maintaining complete insulation coverage.
Data Source
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AI summary
A secondary battery and a battery pack are disclosed. A secondary battery includes an electrode assembly including an electrode tab, a case in which the electrode assembly is accommodated, a connection member electrically connected to the electrode tab, a side terminal electrically connected to the connection member, a cap plate passing through the side terminal and coupled to an opening of the case, and an insulating part insulating the cap plate from the side terminal and insulating the cap plate from the electrode assembly.