Battery Cell Electrode Edge Insulation Against Fin Short Circuits

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Solution Overview

Problem

Battery cells are prone to short circuits due to fins at the edges of substrates piercing barriers during production and fitting, affecting reliability.

Innovation Solution

Incorporating an insulation layer at the edges of electrode substrates to shield fins and prevent them from piercing barriers, thereby reducing the risk of short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If no insulation layer is added at the substrate edge, then the device complexity is low and manufacturing is simple, but the reliability is poor due to fin piercing the barrier causing short circuits

Engineering Contradiction:

Improvebattery cell reliabilityVSAvoidelectrode assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulation layer is added to the substrate edge before assembly, performing the protective function in advance. This preliminary action prevents fin piercing of the barrier before it can cause a short circuit, thereby improving reliability without requiring complex post-assembly modifications

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The insulation layer acts as an intermediary element between the substrate edge and the barrier. It mediates the interaction by providing electrical isolation, preventing direct contact between the fin and barrier, thus eliminating the short circuit risk while maintaining structural simplicity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If an insulation layer is added at the substrate edge, then the reliability improves by preventing short circuits, but the device complexity increases

Engineering Contradiction:

Improvebattery cell reliabilityVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The electrode assembly is segmented into functional zones: the insulation layer is specifically applied only at the substrate edge where fins are present, rather than covering the entire substrate. This segmentation approach adds reliability where needed while minimizing the impact on manufacturing complexity and material usage

Inventive Principle:

Principle #1Segmentation

3Reliability

If the insulation layer covers the entire substrate edge, then the reliability is maximized against fin piercing, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveshort circuit preventionVSAvoidinsulation layer positioning accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The insulation layer is applied with local quality - specifically at the substrate edge region where fins are located, rather than uniformly across the entire substrate. This localized application maximizes reliability where fin piercing is most likely to occur, while reducing the total area requiring precise insulation layer placement, thereby lowering manufacturing precision requirements

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250300336A1Battery cell, battery, and electrical device

Publication Date: 2025.09.25 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

A battery cell, a battery, and an electrical device are disclosed. The battery cell includes an electrode assembly. The electrode assembly includes a first electrode plate. The first electrode plate includes a first substrate. The first substrate includes a first insulation layer at an edge of the first substrate.