Cylindrical Battery Electrode Assembly Insulation for Higher Cell Capacity
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Solution Overview
Problem
The challenge is to reduce the thickness of the insulation member in cylindrical battery cells to minimize space occupation and enhance capacity while ensuring effective insulation and vibration resistance, particularly in larger form factor cells used in electric vehicles.
Innovation Solution
An electrode assembly design with a first electrode current collector having an uncoated region exposed beyond the separator, covered by an insulation member such as an adhesive tape or heat shrink tube, which is wider than the exposed surface and can be segmented and layered to minimize thickness and occupation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of the insulation member is reduced to minimize space occupation, then the capacity of the battery cell increases, but the insulation performance and vibration resistance may deteriorate
Solution Approach 1:
The patent employs composite insulation structures combining multiple materials with different properties. The insulation member consists of a base insulation layer providing electrical isolation and an outer protective layer providing mechanical strength and vibration resistance. This composite approach allows reduced overall thickness while maintaining both insulation performance and structural reliability, thereby increasing battery cell capacity without compromising safety.
Solution Approach 2:
The patent applies local quality by varying the thickness and material properties of the insulation member at different locations. The insulation structure is designed with thicker regions at critical areas requiring enhanced insulation or mechanical protection, and thinner regions where space is less critical. This optimized local distribution maintains reliability while minimizing overall space occupation to maximize battery capacity.
2Quantity of substance
If the thickness of the insulation member is reduced to minimize space occupation, then the capacity of the battery cell increases, but the vibration resistance may deteriorate
Solution Approach 1:
The patent employs composite insulation structures combining multiple materials with different properties. The insulation member consists of a base insulation layer providing electrical isolation and an outer protective layer providing mechanical strength and vibration resistance. This composite approach allows reduced overall thickness while maintaining both insulation performance and structural reliability, thereby increasing battery cell capacity without compromising safety.
Solution Approach 2:
The patent utilizes flexible thin film structures for the insulation member that can conform to the battery can surface and provide effective vibration damping. These thin films are designed with appropriate elasticity and adhesion properties to maintain contact with the battery can during vibration, ensuring continuous insulation and mechanical protection with minimal thickness to maximize capacity.
3Volume of stationary object
If the insulation member is designed to be thinner, then the internal space of the battery can is increased, but the insulation effectiveness may be compromised
Solution Approach 1:
The patent employs composite insulation structures combining multiple materials with different properties. The insulation member consists of a base insulation layer providing electrical isolation and an outer protective layer providing mechanical strength and vibration resistance. This composite approach allows reduced overall thickness while maintaining both insulation performance and structural reliability, thereby increasing battery cell capacity without compromising safety.
Solution Approach 2:
The patent applies parameter changes by optimizing the material composition, thickness, and physical properties of the insulation member to achieve maximum insulation effectiveness at minimum thickness. The insulation material parameters are carefully selected and tuned to provide adequate electrical isolation with reduced thickness, thereby increasing internal space while maintaining insulation effectiveness.
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 reduces insulation member thickness, increasing the size and capacity of the battery cell, enhances vibration resistance, and improves injection molding performance.
Implementation Method 1
insulation member covers an exposed curved surface of a first uncoated region
Data Source
AI summary
An electrode assembly includes a first electrode current collector having a sheet shape, a second electrode current collector having a sheet shape, a separator interposed between the first electrode current collector and the second electrode current collector, the first electrode current collector, the second electrode current collector, and the separator being wound in a winding direction to define a center of the electrode assembly and an outer circumferential surface of the electrode assembly, and an insulation member. The first electrode current collector includes a first uncoated region in which an active material layer is not coated, the first uncoated region forms a plurality of winding turns, and the first coated portion is exposed beyond the separator. The insulation member covers an exposed curved surface of the first uncoated region disposed at an outermost winding turn at the outer circumferential surface of the electrode assembly among the plurality of winding turns.