Battery Cell Insulating Support Structure for Leak and Corrosion Risk
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Solution Overview
Problem
The reliability of battery cells is compromised due to issues such as insulating member detachment, exposure leading to corrosion, and potential electrolyte leakage during the housing process, which affects the stability and safety of the battery.
Innovation Solution
The insulating member is connected to the wall surface of the support distal to the battery cell assembly, reducing tension at the connection point and improving fit reliability, with configurations like annular connections and hot-melting to enhance stability and compatibility across different battery cell sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating member is connected to the battery cell assembly, then the insulating member can provide insulation protection, but the connection position is prone to scratching and pulling apart during housing process
Solution Approach 1:
The support acts as an intermediary component between the insulating member and the housing. The insulating member is connected to the support rather than directly to the battery cell assembly, which prevents the housing from directly contacting and damaging the connection position during the housing process. This intermediary structure resolves the contradiction by providing a stable mounting point that is not susceptible to scratching and pulling apart.
Solution Approach 2:
The support is pre-installed on the battery cell assembly before the housing process. By preparing the support in advance and connecting the insulating member to it, the connection is established before any potential damage can occur during housing. This preliminary action ensures the connection is already in place and protected when the housing operation begins.
2Reliability
If the insulating member is connected to the battery cell assembly, then insulation protection is provided, but the insulating member may detach and cause exposure leading to corrosion
Solution Approach 1:
The support serves as a stable intermediary structure that securely holds the insulating member. By connecting the insulating member to the support rather than directly to the battery cell assembly, the connection is strengthened and less prone to detachment. This prevents exposure of the battery cell assembly to corrosive environments, thereby eliminating the corrosion risk while maintaining insulation reliability.
Solution Approach 2:
The support provides a cushioning effect by absorbing mechanical stresses and preventing direct transmission of forces that could cause the insulating member to detach. This beforehand cushioning protects the insulating member connection from forces that would otherwise lead to detachment and subsequent corrosion exposure.
3Reliability
If the insulating member is fitted closely to multiple circumferential surfaces of the housing, then insulation coverage is improved, but the probability of interfering with fitting position increases
Solution Approach 1:
The support acts as an intermediary that positions the insulating member at a specific location on the battery cell assembly. Instead of the insulating member needing to fit closely to multiple housing surfaces, it is precisely positioned relative to the support. This reduces the number of adjacencies to housing surfaces from multiple to one, thereby reducing interference with fitting position while maintaining adequate insulation coverage.
4Volume of moving object
If the insulating member design is limited by battery cell assembly size, then compactness is achieved, but compatibility and manufacturability are reduced
Solution Approach 1:
The support provides a standardized mounting interface that allows the insulating member design to be decoupled from specific battery cell assembly dimensions. The insulating member can be designed with greater dimensions and standardized features that are compatible across different battery cell sizes, improving universality and manufacturability while the support adapts to the specific assembly size.
Data Source
AI summary
A battery cell, a battery, and an electrical device are provided. The battery cell includes a housing, a core assembly, a support positioned at one end of the core assembly, and an insulating member configured to match the support and wrap the core assembly. The core assembly, support, and insulating member are contained within the housing, with at least a portion of the insulating member connected to a wall surface of the support that is distal to the core assembly. This configuration enhances the connection reliability between the insulating member and the support, reduces the risk of the insulating member detaching, minimizes housing corrosion due to core assembly exposure, mitigates core assembly failure, and decreases the likelihood of electrolyte leakage, thereby improving the reliability and stability of the battery cell.