Battery Electrode Core Spacer Structure for Vibration-Stable Connections
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Solution Overview
Problem
Existing battery designs face issues with connection reliability and stability due to twisting and breaking of connection parts between electrode core sets, especially under vibration and bumpy conditions, leading to safety concerns and poor battery performance.
Innovation Solution
A battery design where every two adjacent electrode core sets are connected in series, with an insulating spacer filled with an insulating material between them, which includes a connection part to enhance the strength and stability of the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple electrode core sets are connected in series to increase battery capacity, then the battery capacity increases, but the connection parts between electrode core sets are prone to be twisted and broken during use
Solution Approach 1:
An insulating spacer is introduced as an intermediary component between adjacent electrode core sets. The spacer includes a gap that receives the connection part, providing mechanical support and isolation. This mediator prevents direct contact between electrode core sets, reducing the risk of twisting and breaking while maintaining electrical connectivity through the designated gap structure.
Solution Approach 2:
The battery structure is segmented into discrete electrode core sets with insulating spacers positioned between them. Each spacer acts as an independent structural unit that supports the connection part, distributing mechanical stresses across multiple localized points rather than allowing continuous stress propagation along the entire series connection.
2Quantity of substance
If multiple electrode core sets are connected in series, then the battery capacity increases, but under vibration and bumpy conditions the electrode core sets move in the housing and generate relative displacement
Solution Approach 1:
The insulating spacer serves as a mediator that physically separates and stabilizes adjacent electrode core sets within the housing. The spacer's structural design with gaps and walls provides mechanical constraints that prevent excessive movement and relative displacement during vibration and bumpy conditions, while still allowing the necessary electrical connections.
Solution Approach 2:
The insulating spacer is positioned in advance between electrode core sets to provide mechanical cushioning and support. The spacer's material properties and structural configuration absorb and distribute mechanical shocks and vibrations before they can cause damage to the electrode core sets or their connections.
3Reliability
If the gap between electrode core sets is filled with insulating material to form an insulating spacer, then the connection stability increases, but the device complexity increases
Solution Approach 1:
The insulating spacer performs multiple functions simultaneously: it provides electrical insulation between adjacent electrode core sets, mechanically supports the connection parts, prevents relative movement during vibration, and maintains the structural integrity of the battery assembly. This multi-functionality reduces the need for separate components for each function.
Solution Approach 2:
The insulating spacer combines several protective and support functions into a single integrated component. Rather than using separate insulating materials, support structures, and positioning elements, the spacer merges these functions into one piece that fills the gap between electrode core sets and provides comprehensive protection and stability.
Data Source
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AI summary
Provided is a battery (100), including a housing (10) and multiple electrode core sets (20) encapsulated in the housing (10). Every two adjacent electrode core sets (20) are connected in series. The electrode core set (20) includes an encapsulation film (201) and at least one electrode core (202), and the electrode core (202) is arranged in an accommodating cavity formed by the encapsulation film (201). The electrode core set (20) includes a first electrode (21) and a second electrode (22). The first electrode (21) and the second electrode (22) protrude out of the encapsulation film (201). The first electrode (21) of one of the two adjacent electrode core sets (20) is electrically connected to the second electrode (22) of the other electrode core set. A gap between the two adjacent electrode core sets (20) is filled with an insulating material so as to form an insulating spacer (30) between the two adjacent electrode core sets (20). A connection part of the two adjacent electrode core sets (20) is arranged in the insulating spacer (30).