Rechargeable Battery Compression Insulator Vibration
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Solution Overview
Problem
Rechargeable batteries face challenges with damage and manufacturability due to loose packaging, which can cause vibration and stress on energy storage cells, especially in moving platforms like vehicles.
Innovation Solution
A method and apparatus for assembling rechargeable batteries that involve inserting energy storage cells into a housing with a base and side portions, securing a housing cover to maintain an insulator in compression between the cells and the cover, using materials like mica sheets to inhibit movement and provide thermal and electrical insulation, and applying a compressive force of at least 1.7 kPa to prevent cell displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batteries are loosely packaged, then ease of manufacture is improved, but reliability deteriorates due to vibration and shaking damage
Solution Approach 1:
The patent applies beforehand cushioning by providing a compressible insulator between the energy storage cells and the housing cover. This insulator is pre-positioned to cushion the cells against vibration and shock during operation, particularly when the battery is used in moving platforms like vehicles. The insulator maintains compression to keep cells stable without requiring complex additional structures.
2Reliability
If a compressible insulator is used to secure cells, then reliability is improved, but device complexity increases
Solution Approach 1:
The housing cover serves multiple functions: it closes the housing, applies compression force to the insulator and cells, and provides structural support. The insulator simultaneously provides electrical insulation, thermal insulation, and mechanical cushioning. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while maintaining improved reliability.
3Reliability
If cells are maintained in compression, then reliability is improved by preventing movement, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by specifying that the insulator be compressed by at least 5% of its thickness, and that a compressive force of at least 1.7 kPa be applied to the cells. These quantitative parameters ensure reliable cell stabilization while providing clear manufacturing specifications that balance precision requirements with manufacturability.
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 solution effectively secures energy storage cells against vibration and stress, enhancing the durability and manufacturability of rechargeable batteries by maintaining cells in compression, thereby reducing the risk of damage and improving their operational stability.
Implementation Method 1
the insulator and the rechargeable energy storage cells are maintained in compression between the housing cover and the housing base portion
Implementation Method 2
using materials like mica sheets to inhibit movement and provide thermal and electrical insulation
Implementation Method 3
using materials like mica sheets to inhibit movement and provide thermal and electrical insulation
Data Source
AI summary
A method of assembling a rechargeable battery is disclosed. The method includes inserting rechargeable energy storage cells into a battery housing, the battery housing having a base portion, a side portion extending from the base portion, and an aperture defined by the side portion, wherein the rechargeable energy storage cells are inserted into the battery housing through the aperture; installing an insulator on the rechargeable energy storage cells; and securing a housing cover to the battery housing such that the insulator and the rechargeable energy storage cells are maintained in compression between the housing cover and the housing base portion. Also disclosed is a rechargeable battery including a battery housing, a housing cover, a plurality of rechargeable energy storage cells disposed within the battery housing, and an insulator disposed between the rechargeable energy storage cells and the housing cover and maintained in compression.