Battery Cap Plate Insulation With Uneven Surface Interlock
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Solution Overview
Problem
Secondary batteries are prone to becoming inoperable due to short circuits when positive and negative polarity parts come into contact, necessitating effective insulation methods to prevent such interactions.
Innovation Solution
The integration of an insulating member with the cap plate and terminal through an insert injection process, utilizing nano-anchors and unevennesses on the surfaces for enhanced adhesion and insulation, thereby preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating member is integrally formed with the cap plate and terminal through insert injection process, then the insulation reliability is improved, but the adhesion strength between the insulating member and the cap plate/terminal deteriorates
Solution Approach 1:
The patent applies preliminary action by forming unevennesses (protrusions or recesses) on the surfaces of the cap plate and terminal before the insert injection process. These pre-formed surface features create mechanical interlocking structures that enhance adhesion strength during the subsequent injection molding of the insulating member, thereby resolving the contradiction between insulation reliability and adhesion strength.
Solution Approach 2:
The patent applies local quality by creating localized unevennesses only at specific contact surfaces between the insulating member and the cap plate/terminal, rather than modifying the entire components. This localized surface treatment provides enhanced adhesion precisely where needed while maintaining the overall integrity and functionality of the components.
2Device complexity
If the insulating member is integrally formed with the cap plate and terminal, then the structural complexity is reduced, but the interface area between components is decreased, leading to poorer adhesion
Solution Approach 1:
The patent applies dimensionality change by transitioning from a flat, two-dimensional contact interface to a three-dimensional interlocking structure through the formation of unevennesses. These protrusions and recesses create additional surface area and mechanical engagement in the vertical dimension, significantly increasing the effective interface area for adhesion while maintaining the integral structure.
3Ease of manufacture
If the insulating member is integrally formed with the cap plate and terminal, then the manufacturing process is simplified, but the crack propagation path is shortened, reducing structural integrity
Solution Approach 1:
The patent applies preliminary action by pre-forming unevennesses on the cap plate and terminal surfaces before the insert injection process. These pre-formed features create extended crack propagation paths and stress distribution patterns that enhance structural integrity, while the entire assembly remains manufacturable through a single integrated injection molding process.
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
This solution significantly improves the adhesion between the cap plate and insulating member, increasing the interface area and crack propagation paths, thus enhancing the battery's operational reliability and preventing short circuits.
Implementation Method 1
At least one of a surface of the cap plate contacting the insulating member and a surface of the terminal contacting the insulating member has an unevenness formed thereon... exhibiting improving adhesion to an insulating member integrally formed with a cap plate and a terminal
Data Source
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AI summary
A secondary battery includes: an electrode assembly including a first electrode plate, a second electrode plate, and a separator; a case accommodating the electrode assembly; a cap plate coupled to the case and having a terminal hole passing therethrough; a terminal over the terminal hole in the cap plate; a current collecting member electrically connecting the electrode plate and the terminal; and an insulating member insulating the cap plate and the terminal from each other and insulating the cap plate and the current collecting member from each other. At least one of a surface of the cap plate contacting the insulating member and a surface of the terminal contacting the insulating member has an unevenness formed thereon.