Battery Cell Insulation Structure for Compact End Cap Assembly
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Solution Overview
Problem
Current battery cell designs have a non-compact internal structure, leading to large external dimensions and low energy density due to the need for sufficient connection areas between insulating films and end caps, which increases the thickness of insulating materials and overall size.
Innovation Solution
The battery cell incorporates a second insulating member with a main body portion and a flanging portion connected to the first insulating member, allowing for reduced thickness and area usage by accommodating the flanging portion within a groove, enabling a compact structure and improved energy density without compromising insulation or assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating member has a sufficient connection area to connect with the flanging portion, then the connection reliability is ensured, but the thickness of the insulating member increases and the battery cell size becomes larger
Solution Approach 1:
The flanging portion is nested within a groove formed on the insulating member, allowing the connection structure to be embedded rather than protruding. This nesting approach ensures sufficient connection area for reliable bonding while keeping the overall thickness of the insulating member compact, as the flanging portion occupies space within the groove rather than adding to the external dimensions.
2Volume of stationary object
If the flanging portion is accommodated within a groove, then the battery cell size is reduced and energy density is improved, but the assembly complexity may increase
Solution Approach 1:
The groove is pre-formed on the insulating member during its manufacturing process, before assembly. The flanging portion is then simply placed into the pre-prepared groove and connected, eliminating the need for complex real-time alignment or additional machining steps during assembly. This preliminary preparation of the groove structure reduces assembly complexity while achieving the space-saving benefit.
3Volume of stationary object
If the insulating member thickness is reduced for compact structure, then energy density is improved, but the connection area between insulating member and flanging portion becomes insufficient
Solution Approach 1:
Instead of increasing connection area by adding thickness in the vertical dimension, the solution transitions to utilizing the horizontal dimension by forming a groove on the surface of the insulating member. The flanging portion connects to the groove laterally, providing sufficient connection area without requiring increased thickness, thus maintaining compact battery cell dimensions while ensuring reliable connection.
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 enhances the energy density and compactness of the battery cell by reducing material thickness and area usage, while maintaining reliable insulation and simplified assembly processes, thereby addressing the limitations of existing designs.
Implementation Method 1
the first flanging portion is hot-melted to the side of the first insulating member facing the end cap or the side of the first insulating member away from the end cap
Data Source
AI summary
A battery cell includes a shell; an electrode assembly; and an end cap assembly, including an end cap, a first insulating member and a second insulating member, where the first insulating member is arranged between the electrode assembly and the end cap, so as to insulate and isolate the electrode assembly from the end cap, the second insulating member includes a main body portion and a first flanging portion, the first flanging portion is connected to one end of the main body portion, the main body portion is arranged between the shell and the electrode assembly, so as to insulate and isolate the shell from the electrode assembly, and the first flanging portion is connected to a side of the first insulating member facing the end cap or a side of the first insulating member away from the end cap.