Battery Cell Insulation Bonding Without Box Beams
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Solution Overview
Problem
Current battery designs face challenges in balancing energy density and safety, as structural components like box beams can lead to risks of electric leakage and short circuits while attempting to improve energy density by removing these components.
Innovation Solution
The battery design incorporates a shell with a first convex part and an insulation layer that bonds directly to a cover piece, eliminating the need for structural components like box beams, while ensuring the electrode terminal is insulated and isolated from the cover piece, thereby preventing leakage and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If structural components like box beams are used to improve safety, then reliability is improved, but device complexity increases and energy density decreases
Solution Approach 1:
The patent removes traditional box beam structural components from the battery assembly and replaces them with insulation layers integrated directly onto the battery cell shells. This extraction of unnecessary structural elements simplifies the overall device complexity while maintaining safety functions through the insulation layers that provide both mechanical support and electrical isolation.
Solution Approach 2:
The insulation layer serves multiple functions simultaneously: it provides electrical insulation to prevent short circuits, acts as a structural bonding surface to connect battery cells to the cover piece, and eliminates the need for separate box beam components. This multi-functionality resolves the contradiction by maintaining reliability without increasing device complexity.
2Quantity of substance
If structural components like box beams are removed to improve energy density, then device complexity decreases, but reliability deteriorates due to increased risk of electric leakage and short circuits
Solution Approach 1:
The patent merges the insulation function with the structural bonding function by integrating the insulation layer directly onto the battery cell shell. This combined structure eliminates the need for separate box beams, thereby improving energy density, while simultaneously maintaining reliability through the insulating properties that prevent electric leakage and short circuits.
Solution Approach 2:
The insulation layer acts as an intermediary element between the battery cell shell and the cover piece, providing electrical isolation to prevent short circuits while also serving as the bonding interface for structural connection. This intermediary structure ensures reliability is maintained even after removing traditional structural components.
3Reliability
If insulation layer height is increased to ensure electrode terminal isolation, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by varying the height of the insulation layer in different regions. The insulation layer is made higher specifically at positions where electrode terminals are located to ensure adequate isolation, while other regions can have reduced insulation layer height. This localized approach improves reliability for critical isolation points without unnecessarily increasing device complexity across the entire structure.
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 energy density and safety by reducing the risk of electric leakage and short circuits, while also simplifying the battery structure and improving overall structural strength.
Implementation Method 1
the insulation layer is configured for bonding with the cover piece covering the opening to fixedly connect the multiple battery cells to the cover piece
Data Source
AI summary
A battery includes multiple battery cells, each battery cell includes shell, electrode terminal, and insulation layer, the shell includes a first wall, which includes a body and a first convex part, the body has an inner surface and an outer surface arranged oppositely in the thickness direction thereof, the first convex part protrudes from the outer surface in a direction away from the inner part of the battery cells, the electrode terminal is arranged on the body, and the insulation layer covers and is fixed on the first convex part; and a box, provided with an accommodating cavity with an opening, wherein the multiple battery cells are accommodated in the accommodating cavity, and the insulation layer binds with the cover piece covering the opening to fixedly connect the multiple battery cells to the cover piece.