Battery Case Assembly With Nested Insulation for Stable Terminal Connection
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Solution Overview
Problem
Existing secondary batteries face challenges in ensuring effective electrical insulation and secure connection between components, leading to potential short circuits and reduced stability during charging and discharging processes.
Innovation Solution
The secondary battery design incorporates a case assembly with a terminal plate, outer and inner insulators, and a cover portion, featuring a protrusion and uncoated portions for electrode connection, along with an adhesive layer and pressurizing protrusions to ensure stable electrical connections and insulation, using materials like polypropylene and aluminum for enhanced conductivity and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods are used between electrodes and terminals, then assembly is simple, but electrical connection stability is poor leading to potential short circuits
Solution Approach 1:
The case assembly is divided into distinct functional components: outer insulator for electrical isolation, inner insulator for additional insulation layer, terminal plate for electrical connection, and cover portion for sealing. This segmentation allows each component to perform its specific function optimally, ensuring reliable electrical connections while maintaining manageable structural complexity
Solution Approach 2:
The insulators are positioned nested within the case structure, with the outer insulator between the case and terminal plate, and the inner insulator between the case and electrode assembly. This nested arrangement provides multiple insulation layers in a compact configuration, enhancing electrical connection stability without proportionally increasing overall device complexity
2Reliability
If adequate electrical insulation is implemented between components, then short circuit risk is reduced, but the number of insulating components increases
Solution Approach 1:
The outer insulator and inner insulator are integrated into the case assembly structure, with the terminal plate serving dual purposes as both an electrical connection element and a mounting structure for the outer insulator. This merging approach provides comprehensive electrical insulation while minimizing the number of separate components
Solution Approach 2:
The terminal plate performs multiple functions: it provides electrical connection to the electrode assembly, serves as a mounting structure for the outer insulator, and contributes to the overall structural integrity of the case assembly. This multi-functionality reduces the need for additional dedicated insulation components
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
The design enhances electrical insulation and connection stability, reducing the risk of short circuits and improving the overall performance and safety of the secondary battery.
Implementation Method 1
an adhesive layer coated on the thread
Implementation Method 2
an outer insulator between the case and the terminal plate, the outer insulator electrically insulating between the case and the terminal plate
Implementation Method 3
an inner insulator on an inner circumferential surface of the case, the inner insulator electrically insulating between the case and the electrode assembly
Implementation Method 4
a pressurizing protrusion that protrudes from the inner circumferential surface and comes into contact with the electrode assembly
Data Source
AI summary
A secondary battery includes an electrode assembly including a first electrode, a separator, and a second electrode, a case assembly having one opened side, the case assembly accommodating the electrode assembly therein, and a cover portion screwed to the opened side of the case assembly. The case assembly of the secondary battery includes a case having one opened side and another side opposite the one opened side with a through hole therein, a terminal plate on an outer circumferential surface of the case, the terminal plate comprising a protrusion inserted into the through hole, an outer insulator between the case and the terminal plate, the outer insulator electrically insulating between the case and the terminal plate, and an inner insulator on an inner circumferential surface of the case, the inner insulator electrically insulating between the case and the electrode assembly.