Rechargeable Battery Fuse Embedding with Exposing Hole
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Solution Overview
Problem
Rechargeable batteries face safety risks due to sparks and molten fuse material potentially damaging the electrode assembly, especially in mechanically unstable environments, as they can cause fires or explosions.
Innovation Solution
Incorporating a synthetic material with an exposing hole in the terminal connection portion to embed the fuse, which prevents sparks and molten material from contacting the electrode assembly, and includes polyethyletherketone or similar injection molding materials for enhanced safety and structural integrity, allowing pressure venting without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse is embedded in the terminal connection portion without protection, then the battery structure is simple, but sparks and molten fuse material can contact the electrode assembly causing fire or explosion
Solution Approach 1:
The patent introduces a protective material as an intermediary substance between the fuse and the electrode assembly. This material contains the fuse within a cavity and prevents direct contact between sparks/molten material and the electrode assembly, thereby resolving the safety issue without significantly complicating the overall structure.
Solution Approach 2:
The fuse is nested within a cavity formed in the protective material, which itself is embedded in the terminal connection portion. This nested structure provides protection while maintaining a compact design, addressing both safety concerns and structural simplicity.
2Reliability
If the terminal connection portion is exposed without embedding, then the synthetic material can be easily manufactured, but sparks and molten fuse material can travel freely and damage the electrode assembly
Solution Approach 1:
The protective material acts as a flexible shell or encapsulating film that contains the fuse and prevents harmful material ejection. This approach provides effective protection while being compatible with standard manufacturing processes for battery components.
3Reliability
If the fuse is completely enclosed in the synthetic material, then safety is improved, but high pressure from heat cannot be vented and may damage the synthetic material
Solution Approach 1:
The protective material incorporates a porous structure with controlled void spaces that allow pressure and heat to be vented safely. The porosity enables gas escape paths while the material structure remains intact, preventing both uncontrolled ejection and structural failure.
Solution Approach 2:
The protective material is segmented into regions: a dense outer layer for containment and protection, and an inner porous region for pressure relief. This segmentation allows the material to simultaneously provide safety containment and pressure venting capabilities.
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 solution effectively contains sparks and molten fuse material, preventing damage to the electrode assembly and reducing the risk of fires or explosions, while maintaining structural integrity and allowing pressure release, thus enhancing safety in various usage conditions.
Implementation Method 1
In case the fuse melts, heated-up gas, a spark or the molten fuse material may affect the electrode assembly
Implementation Method 2
Due to the exposing hole of the synthetic material, high pressure that may arise from heat caused by the melting fuse can be vented without damaging the synthetic material
Data Source
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AI summary
A rechargeable battery (100) including an electrode assembly (10) that is adapted to perform a charge and discharge operation; a case (15) that houses the electrode assembly (10); a cap plate (20) coupled to and closing an opening of the case (15); an electrode terminal (21, 22); and a lead tab (51) that connects the electrode assembly (10) to the electrode terminal (21, 22), wherein the lead tab (51) includes a current collecting connection portion (511) that is connected to the electrode assembly (10); a terminal connection portion (512) that is bent from the current collecting connection portion (511) to be connected to the electrode terminal (10); and a synthetic material (514) that embeds the terminal connection portion (512) in which a fuse (513) is formed, and wherein the synthetic material (514) includes an exposing hole (515) therein, the exposing hole (515) exposing at least one side of the fuse (513).