Battery Cell Insulation via Partial Electrode Lead Coating
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Solution Overview
Problem
The challenge lies in maintaining high insulation reliability of electrode leads in battery packs while ensuring standardized manufacturing processability, particularly in pouch type battery cells, where adjacent electrode leads can easily short-circuit when stacked, and adding insulation members increases costs and complexity.
Innovation Solution
A battery pack design where an insulating member is attached to at least 60% of the electrode leads' protruding area, ensuring insulation reliability while allowing restricted exposure for electrical connection, using a laminate sheet battery case with a durable outer resin layer and a polyolefin-based resin sealant for thermal bonding, and an embossing structure on the insulating film to prevent unwanted contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating member is attached to electrode leads to prevent short-circuits, then insulation reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The insulating member is integrated with the electrode lead to form a single combined structure. The insulating layer is formed directly on the electrode lead surface through coating processes, merging the electrical conductor and insulator into one unified component, thereby preventing short-circuits without adding separate insulating parts
Solution Approach 2:
The insulating member serves multiple functions simultaneously: it provides electrical insulation to prevent short-circuits between adjacent leads, acts as a protective coating during manufacturing processes, and maintains structural integrity of the electrode lead assembly. This multi-functionality reduces the need for additional separate components
2Reliability
If an insulating member is attached to electrode leads, then insulation reliability is improved, but manufacturing cost increases
Solution Approach 1:
The insulating layer is formed on the electrode lead surface before the electrode lead is assembled into the battery pack. This preliminary insulation treatment allows for simple coating processes to be performed during electrode lead manufacturing, avoiding the need for complex post-assembly insulation operations and reducing overall manufacturing costs
Solution Approach 2:
The mechanical attachment of separate insulating components is replaced by forming an insulating coating layer directly on the electrode lead surface through chemical or physical vapor deposition, sol-gel processes, or solution coating methods. This substitution eliminates mechanical assembly steps and reduces manufacturing complexity
3Productivity
If electrode leads are positioned adjacent to each other for stacking, then productivity is improved, but risk of short-circuit increases
Solution Approach 1:
The insulating member is applied selectively to specific regions of the electrode lead where short-circuit risks exist, such as the exposed portions and areas adjacent to other leads. This localized insulation approach maintains high stacking efficiency while providing targeted protection against short-circuits in critical areas
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 effectively maintains insulation between electrode leads, preventing short-circuits while allowing necessary electrical connections, enhancing manufacturing efficiency and cost-effectiveness by standardizing the insulation structure without altering the battery cell shape or process.
Implementation Method 1
a polyolefin-based resin sealant layer which exhibits a thermal bonding property
Data Source
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AI summary
A battery cell has a structure in which outer peripheral portions of a battery case are sealed by thermal bonding in a state in which an electrode assembly is mounted together with an electrolyte in a battery case made of a laminate sheet, wherein a pair of electrode leads of the electrode assembly protrude outward from the battery case, and an insulating member is attached to each of the electrode leads in an area of at least 60% of a total area of the electrode leads that protrude outwardly.