Insulating Casing Overlap Structure for Battery Swelling Control
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Solution Overview
Problem
Existing secondary batteries lack an effective reinforcing structure for the insulating casing, which can lead to swelling and potential structural instability during use.
Innovation Solution
The secondary battery incorporates an insulating casing with a transverse overlapping portion and longitudinal overlapping portions formed by thermal fusion or adhesive means, providing enhanced structural reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple insulating casing is used, then the manufacturing cost is reduced, but the structural stability deteriorates leading to swelling
Solution Approach 1:
The insulating casing is divided into multiple separate casing pieces that are assembled together to form the complete casing structure. This segmentation allows for better structural distribution and stability while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
Reinforcing ribs are added to the casing pieces, extending the structure from a flat 2D surface into a 3D form with enhanced rigidity. These ribs create additional structural dimensions that prevent swelling without significantly increasing manufacturing complexity
2Strength
If the insulating casing is made thicker, then the structural strength is improved, but the battery volume increases
Solution Approach 1:
Instead of uniformly thickening the entire casing, the structure is segmented into thin casing pieces with localized reinforcing ribs. This provides high structural strength at specific critical points while keeping the overall material usage and volume low
Solution Approach 2:
The reinforcing ribs are strategically positioned at locations where structural support is most needed, such as at corners and along edges. This local reinforcement approach provides maximum strength with minimum material, avoiding unnecessary volume increase
3Reliability
If reinforcing ribs are added to the insulating casing, then the resistance to swelling is improved, but the device complexity increases
Solution Approach 1:
The casing is divided into multiple simple pieces that can be manufactured using standard processes. Each piece has integrated reinforcing ribs that are formed as part of the molding process, avoiding complex assembly steps while achieving high swelling resistance
Solution Approach 2:
The reinforcing ribs are designed with optimized dimensions and spacing parameters that can be adjusted based on specific application requirements. This allows the same basic structural concept to be adapted to different battery sizes and shapes without fundamentally changing the design complexity
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 reinforced insulating casing effectively limits expansion and enhances structural stability, preventing swelling and ensuring the integrity of the battery.
Implementation Method 1
The insulating casing may include a plurality of insulating casing pieces joined to one another
Implementation Method 2
The insulating casing may include a plurality of insulating casing pieces joined to one another through thermal fusion or an adhesive means
Data Source
AI summary
A secondary battery is disclosed. The secondary battery includes an electrode assembly, an insulating casing accommodating the electrode assembly therein, and a case accommodating the insulating casing therein. The insulating casing includes an upper insulating casing having a first traverse overlapping portion, and a lower insulating casing having a second traverse overlapping portion overlapping the first traverse overlapping portion to form a traverse overlapping portion.