Battery Cell Insulator Overlap Structure for Gap-Free Adhesion
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Solution Overview
Problem
Conventional insulators in batteries face difficulties in fitting and have poor fitting effects, leading to potential short circuits due to large gaps and exposure of adhesive regions, which can result in partial detachment and increased risk of short circuits.
Innovation Solution
The design incorporates insulators with both adhesive and non-adhesive regions, where the non-adhesive regions overlap to form specific overlapping regions, allowing for improved fitting and adhesion without affecting the bent parts, and are fixedly connected using a third insulator or adhesive, reducing the risk of gaps and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulators are used to cover the electrode pins, then insulation protection is provided, but the fitting effect is poor and large gaps are formed leading to short circuit risk
Solution Approach 1:
The insulator is divided into multiple insulator pieces, each covering different portions of the electrode pin. This segmentation allows each piece to be precisely positioned and fitted to specific areas, eliminating large gaps while maintaining insulation protection. The multiple pieces can be independently adjusted and secured to achieve better overall coverage.
Solution Approach 2:
The insulator pieces are arranged in multiple layers at different positions along the electrode pin, creating a multi-dimensional coverage structure. This layered approach allows the insulators to wrap around the pin more completely, filling gaps that would exist with single-layer coverage and improving the overall fitting effect.
2Strength
If adhesive is applied to the insulator surface, then adhesion is provided, but adhesive exposure in partial regions causes decreased adhesiveness and partial detachment
Solution Approach 1:
Each insulator piece is designed with adhesive regions and non-adhesive regions in specific patterns. The adhesive regions are positioned to contact the electrode pin surface where bonding is needed, while non-adhesive regions are positioned to overlap with adjacent insulator pieces. This local differentiation ensures proper adhesion without adhesive exposure that would cause detachment.
Solution Approach 2:
Adjacent insulator pieces are designed with overlapping regions where their non-adhesive areas meet and combine to form continuous coverage. This merging of insulator pieces creates a unified insulating structure where the overlapping regions eliminate gaps and the combined adhesive regions provide stable bonding without exposure.
3Reliability
If insulators are fitted tightly to prevent gaps, then short circuit risk is reduced, but fitting difficulty increases
Solution Approach 1:
By dividing the insulator into multiple manageable pieces, each piece can be independently fitted and positioned on the electrode pin. This segmentation reduces the complexity of fitting compared to installing a single large insulator, while the combined coverage of all pieces achieves tight gap-free insulation that prevents short circuits.
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 design enhances the fitting effect, prevents large gaps and metal exposure, reduces the risk of short circuits, and improves the reliability and safety of the battery by ensuring secure adhesion and insulation.
Implementation Method 1
At least one of the first insulator and the second insulator includes an adhesive region and a non-adhesive region
Data Source
AI summary
A cell, a battery, and an insulator adhesion method are provided. The cell includes an electrode assembly, a pin, a first insulator, and a second insulator. The electrode assembly includes a tab. The connector includes a post terminal connection part and a tab connection part. The post terminal connection part is connected to a post terminal of the cell, and the tab connection part is connected to the tab. The first insulator at least partially covers a surface of the tab connection part close to the electrode assembly. The second insulator at least partially covers the post terminal connection part. At least one of the first insulator and the second insulator includes an adhesive region and a non-adhesive region while the non-adhesive region of one insulator in the first insulator and the second insulator at least partially overlaps with the other insulator to form an overlapping region.