Secondary Battery Insulation Case Recess Design
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Solution Overview
Problem
Conventional insulation cases in secondary batteries face deformation issues during injection molding, making it difficult to maximize battery capacity due to thin base plates, and external forces can cause deformation, while thickening the base plate reduces capacity to prevent deformation.
Innovation Solution
A secondary battery design featuring a thick insulation case with recesses that receive parts of the cap assembly, minimizing unnecessary space and preventing deformation by forming a stepped recess configuration that complements the cap assembly's shape, ensuring secure contact and reducing the risk of fluctuation or external damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the plate forming the base of the insulation case is made thin to maximize electrode assembly size, then battery capacity is improved, but the insulation case becomes deformed during injection molding and by external forces
Solution Approach 1:
The insulation case is divided into a base plate and a side wall that extends upwardly from the edge of the base plate. This segmentation allows the side wall to provide structural support and resistance against deformation while keeping the base plate thin to maximize electrode assembly size and battery capacity.
Solution Approach 2:
The insulation case structure transitions from a two-dimensional thin plate to a three-dimensional structure by extending a side wall upwardly from the base plate. This dimensional change adds structural strength and deformation resistance without significantly increasing the footprint area, allowing the base plate to remain thin while providing overall structural stability.
2Stability of the object's composition
If the plate forming the base of the insulation case is made thick to prevent deformation, then insulation case stability is improved, but battery capacity is reduced due to decreased electrode assembly size
Solution Approach 1:
The insulation case is segmented into a thin base plate and a separate side wall structure. The side wall extends upwardly from the base plate's edge, concentrating the structural support function in the side wall while allowing the base plate to remain thin, thus maximizing the space available for the electrode assembly and battery capacity.
Solution Approach 2:
Instead of increasing the base plate thickness in the vertical direction, the design adds a side wall that extends upwardly from the base plate's edge. This utilizes the vertical dimension more efficiently, providing structural stability without consuming additional base plate thickness that would reduce electrode assembly space.
3Volume of moving object
If the height of the side wall is low to minimize battery size, then battery compactness is improved, but the insulation case becomes easily deformed by external forces
Solution Approach 1:
The insulation case is formed as a composite structure with a base plate and an integrated side wall. This composite design creates a more rigid overall structure that resists external forces better than a simple thin plate, while maintaining compact dimensions. The side wall acts as a structural reinforcement that increases strength without proportionally increasing volume.
Data Source
AI summary
A secondary battery includes an insulation case that is thickly formed to prevent deformation and that includes a recess that receives at least a part of a cap assembly in the insulation case so as minimize unnecessary space between the cap assembly and the insulation case.