Battery Feed-Through Compression Joint Insulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current insulation schemes in lithium batteries, particularly in implantable medical devices, fail to prevent lithium cluster formation that can lead to short circuits, and rely heavily on adhesives which increase complexity and introduce failure points.

Innovation Solution

A feed-through insulation method using thermoplastic materials like polypropylene or polyether ether ketone, disposed through injection molding and forming a compression joint with an insulation layer, eliminates the need for adhesives and provides a robust seal against lithium cluster formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesives are used to secure insulation schemes, then the insulation can be attached to prevent physical contact between anode and cathode, but the device complexity and manufacturing expense increase

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the chemical bonding mechanism (adhesives) with a mechanical compression joint system. The feed-through assembly includes a compression joint that mechanically secures the insulation layer through compressive force, eliminating the need for adhesives while maintaining insulation effectiveness and reducing manufacturing complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the adhesive layer from the insulation system, replacing it with a self-contained compression joint mechanism integrated into the feed-through assembly. This removal of the adhesive component simplifies the overall structure and reduces manufacturing steps while maintaining functional effectiveness

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If current insulation schemes are used to prevent physical contact, then anode and cathode surfaces are protected from direct contact, but lithium cluster formation around insulators still creates shorts

Engineering Contradiction:

Improvecontact preventionVSAvoidlithium cluster formation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a compression joint system that creates a tight, flexible seal around the insulation layer. This compression mechanism prevents lithium clusters from forming around the insulator by maintaining continuous mechanical pressure that blocks cluster growth pathways, while still allowing for thermal expansion and manufacturing tolerances

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The compression joint is designed to preemptively prevent lithium cluster formation by maintaining constant compressive force on the insulation layer. This preliminary protective action blocks the initiation and growth of lithium clusters before they can create conductive pathways, rather than merely preventing direct contact between electrodes

Inventive Principle:

Principle #9Preliminary anti-action

3Device complexity

If feed-through assembly with compression joint is used, then adhesive-free insulation is achieved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoiddimensional tolerance

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent employs compression joint design parameters that accommodate normal manufacturing variations. By optimizing the compression force, joint geometry, and material properties, the system maintains effective insulation without requiring extremely tight dimensional tolerances, thus balancing manufacturing simplicity with adequate precision requirements

Inventive Principle:

Principle #35Parameter changes

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 solution effectively reduces lithium cluster formation, enhances battery longevity, simplifies manufacturing, and reduces failure points by creating a secure, adhesive-free insulation that withstands mechanical stress and corrosive environments.

Implementation Method 1

the insulation layer forms a compression joint with the feed through insulation disposed over the feed-through assembly

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS9281507B2Battery having feed-through assembly forming compression joint with insulation layer and method for making the same

Publication Date: 2016.03.08 PACESETTER INC

AI summary

A battery includes a case having a lid. A feed-through assembly provides an electrical connection through the lid. Feed-through insulation is disposed over the feed-through assembly. An insulation layer is disposed over the inner surface of the lid and the feed-through assembly. The insulation layer comprises an aperture configured to accommodate the feed-through assembly and to form a compression joint with the feed-through insulation disposed over the feed-through assembly.