Battery Cell Empty Foil Layout for Impact Short-Circuit Prevention
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Solution Overview
Problem
Conventional batteries are prone to short circuits when dropped or impacted due to internal cell collisions with the packaging shell and blank foil, leading to potential debris generation.
Innovation Solution
A battery design with a packaging shell and a battery cell featuring empty foil areas on either side of the electrode plates, where the width of these areas is optimized to be less than or equal to 40% of the battery cell's width, adhered to the shell with a bonding member, reducing the risk of debris formation upon impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery cell is packaged in the packaging shell, then the battery structure is complete and functional, but the battery cell may collide with the packaging shell during impact, causing the blank foil to break and leading to short circuit
Solution Approach 1:
The patent applies beforehand cushioning by designing empty foil areas (without active material) at the four corners of the electrode plate, positioned at the outermost circle of the battery cell. These empty foil areas serve as pre-positioned cushion zones that absorb impact energy before it reaches the active material and current collector, preventing blank foil breakage and short circuits during drop or impact events.
Solution Approach 2:
The patent applies local quality by creating localized empty foil areas only at the four corners of the electrode plate, while the central active material areas remain intact. This localized modification targets the specific impact-prone zones (corners) without compromising the overall energy storage capacity and functional areas of the battery cell.
2Strength
If empty foil areas are added to the electrode plate to reduce impact damage, then the drop resistance improves, but the active material area and energy density may be reduced
Solution Approach 1:
The patent minimizes the impact on active material area by placing empty foil areas only at the four corners of the electrode plate, where impact forces are most concentrated. The central and edge regions that contribute to energy storage remain fully populated with active material, thus optimizing the balance between drop resistance and energy density.
Solution Approach 2:
The patent uses a moderate extent of empty foil areas (controlled by the parameter 0 ≤ (W1+W2)/W ≤ 40%) to achieve sufficient impact protection without over-designing. This partial action approach provides adequate cushioning at the corners while preserving the majority of the active material area for energy storage.
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 optimized empty foil areas reduce the likelihood of debris generation during impacts, thereby minimizing the risk of short circuits and enhancing the battery's drop and impact resistance.
Implementation Method 1
At least one of the first surface and the second surface is adhered to the packaging shell by a bonding member
Data Source
AI summary
A battery includes a packaging shell and a battery cell. The battery cell is disposed in the packaging shell, the battery cell includes a first electrode plate, the first electrode plate includes a first empty foil area and a second empty foil area where no active material is disposed on either side of the first electrode plate. The first empty foil area is arranged on a first surface, the second empty foil area is arranged on a second surface. At least one of the first surface and the second surface is adhered to the packaging shell by a bonding member. In a width direction of the battery cell, a width of the battery cell is W, a width of the first empty foil area is W1, a width of the second empty foil area is W2, and 0≤(W1+W2)/W≤40%.