Interference-Fit Battery Case Assembly With Insulating Gasket
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing secondary battery designs face challenges in reducing production costs while ensuring electrical safety and preventing short circuits.
Innovation Solution
The secondary battery design incorporates a first case and a second case coupled with an interference fit, using an insulating gasket made of materials like polypropylene, polybutylene terephthalate, or polytetrafluoroethylene, to prevent electrical connection and enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding process is used to couple cases, then connection strength is improved, but production cost increases
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical interference fit system. The first case and second case are coupled through direct mechanical interference without welding, thereby eliminating welding costs while maintaining connection strength. This is achieved through precisely engineered interference dimensions between the cases that create sufficient mechanical bonding force.
2Reliability
If conductive gasket is used to couple cases, then sealing performance is improved, but risk of short circuit increases
Solution Approach 1:
The patent introduces an insulating gasket as an intermediary component between the first case and second case. This gasket serves dual functions: providing sealing performance through its elastic deformation to fill gaps, and preventing electrical conduction between the conductive cases. The insulating material acts as a mediator that simultaneously addresses sealing and electrical isolation requirements.
Solution Approach 2:
The insulating gasket is made from composite or blended rubber materials that combine sealing properties with electrical insulation characteristics. This composite material approach allows the single component to fulfill both sealing and electrical isolation functions without requiring additional conductive or insulating layers.
3Reliability
If insulating gasket is added to prevent short circuit, then electrical safety is improved, but device complexity increases
Solution Approach 1:
The insulating gasket is designed to perform multiple functions simultaneously: sealing between cases, preventing electrical conduction, and providing mechanical cushioning. By making this single component multi-functional, the patent avoids adding separate elements for each function, thereby improving electrical safety without proportionally increasing structural complexity.
Solution Approach 2:
The patent merges the sealing function and electrical insulation function into a single insulating gasket component. Instead of using separate sealing gaskets and insulating barriers, these functions are combined in one element that is installed in a single step, simplifying the assembly process and reducing the number of parts.
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 design reduces production costs and effectively prevents short circuits by using an insulating gasket to electrically disconnect the cases, ensuring electrical safety and efficient electrolyte containment.
Implementation Method 1
an insulating gasket positioned between the first case and the second case and coupled to at least one of the first case or the second case
Implementation Method 2
the insulating gasket may be elastic, and the first case and the second case may be coupled to each other with an interference fit with the insulating gasket interposed between the first case and the second case
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A secondary battery is provided that is has reduced production cost. The secondary battery includes an electrode assembly, including a first electrode plate, a second electrode plate, and a separator. A first case surrounds a first surface of the electrode assembly, and a second case surrounds a second surface of the electrode assembly that is opposite to the first surface. An insulating gasket is positioned between the first case and the second case and coupled to at least one of the first case or the second case. The first case and the second case are coupled to each other with an interference fit with the insulating gasket interposed between the first case and the second case.