Secondary Battery Case Assembly Using Insulated Interference Fit
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Solution Overview
Problem
Existing secondary batteries 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 polyimide, to prevent electrical connection between the cases 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 system) with a mechanical interference fit system. The first case and second case are coupled through direct mechanical engagement without welding, thereby eliminating welding costs while maintaining connection strength through precise dimensional design and interference fit mechanics.
2Reliability
If conductive material is used for cases, then electrical conductivity is improved, but risk of short circuit increases
Solution Approach 1:
The patent introduces an insulating gasket as an intermediary element between the first case and second case. This gasket is made of insulating material and is positioned at the coupling interface, thereby maintaining the electrical insulation function while allowing the cases themselves to be made of conductive material for structural integrity and conductivity where needed.
3Reliability
If insulating gasket is added, then electrical safety is improved, but device complexity increases
Solution Approach 1:
The insulating gasket serves multiple functions simultaneously: it provides electrical insulation between cases, acts as a sealing element to prevent electrolyte leakage, and facilitates the mechanical coupling of cases through the interference fit structure. By combining multiple functions into a single component, the overall device complexity is minimized while achieving comprehensive safety and functionality.
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 ensure electrical disconnection between the cases, enhancing safety and efficiency.
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 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
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.