Insulating Member Design for Battery Terminal Welding Heat

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Solution Overview

Problem

Rechargeable battery modules face issues with insulating members melting or generating smoke during laser welding of busbars to electrode terminals, leading to strength deterioration and external appearance failures.

Innovation Solution

The integration of an insulating member that supports the electrode terminal on the cap plate, featuring a heat avoidance space and multiple insulating portions to prevent welding heat from affecting the battery structure, ensuring stable support and preventing melting during welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If laser welding is used to connect busbar to electrode terminal, then connection strength is improved, but insulating member melts and generates smoke

Engineering Contradiction:

Improveconnection strengthVSAvoidmelting and smoke generation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The insulating member is divided into multiple portions: a first insulating portion positioned away from the welding area to avoid heat exposure, and a second insulating portion positioned near the welding area to provide local insulation. This segmentation allows the insulating member to maintain its function while avoiding damage from welding heat.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second insulating portion acts as an intermediary between the welding area and the main body of the insulating member, absorbing and isolating the welding heat to prevent it from reaching and damaging the first insulating portion. This mediator approach protects the insulating member from harmful thermal effects.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If insulating member is positioned close to electrode terminal for support, then support stability is improved, but welding heat affects the insulating member

Engineering Contradiction:

Improvesupport stabilityVSAvoidwelding heat exposure

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The insulating member is segmented into a first insulating portion that provides stable support by being positioned away from the welding area, and a second insulating portion that is positioned near the welding area to provide local insulation without compromising the overall stability. This segmentation allows the support function to be maintained while avoiding heat exposure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the insulating member have different spatial relationships to the welding area: the first insulating portion is located in a low-heat zone for stable support, while the second insulating portion is located in a high-heat zone to provide localized insulation protection. This local quality differentiation optimizes both support stability and heat resistance.

Inventive Principle:

Principle #3Local quality

3Reliability

If insulating member is made larger to improve insulation coverage, then insulation effectiveness is improved, but welding heat exposure increases

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidwelding heat exposure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The insulating member is divided into a first insulating portion with larger area for effective insulation coverage, and a second insulating portion with smaller area positioned near the welding area. This segmentation allows the majority of the insulating member to provide effective insulation while minimizing the portion exposed to welding heat.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating member exhibits local quality variation where the first insulating portion has larger dimensions for comprehensive insulation coverage in low-heat zones, while the second insulating portion has reduced dimensions to minimize heat exposure in high-heat zones. This local quality optimization balances insulation effectiveness with heat resistance.

Inventive Principle:

Principle #3Local quality

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 insulating member effectively prevents melting and supports the electrode terminal, maintaining structural integrity and appearance by isolating the welding heat, thus enhancing the reliability of rechargeable battery modules.

Implementation Method 1

an insulating member that electrically insulates the cap plate and the electrode terminal while partially supporting the electrode terminal at an outer surface of the cap plate

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

due to a welding heat occurring upon laser welding

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS9899642B2Rechargeable battery and module thereof

Publication Date: 2018.02.20 SAMSUNG SDI CO LTD

AI summary

A rechargeable battery includes an electrode assembly; a case housing the electrode assembly; a cap plate sealing an opening of the case; an electrode terminal that is electrically connected to the electrode assembly and extends through a terminal hole of the cap plate and is oriented outside of the cap plate; and an insulating member that electrically insulates the cap plate and the electrode terminal while supporting the electrode terminal at an outer surface of the cap plate.