Integrated Battery Insulator for Electrode Shape and Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing secondary batteries face challenges in maintaining insulating performance and electrode assembly shape, which affects their energy density, output, and stability, particularly in high-capacity applications like electric vehicles.
Innovation Solution
A secondary battery design that incorporates a single insulator component with distinct portions - an insulating upper portion, an insulating side portion, and an insulating core portion - to maintain insulation and support the electrode assembly's shape, thereby enhancing energy density and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate insulator components are used to maintain insulating performance and electrode assembly shape, then insulating performance and shape maintenance are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple separate insulator components (insulating upper portion, insulating side portion, and insulating core portion) into a single integrated insulator component. This merging maintains the insulating performance and shape support functions while reducing the number of components and simplifying the assembly process, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The single insulator component is designed to perform multiple functions simultaneously: the insulating upper portion covers the upper side of the electrode assembly, the insulating side portion maintains the side shape, and the insulating core portion provides internal support. This multi-functionality allows one component to replace multiple separate components, reducing complexity while maintaining insulating performance.
2Shape
If multiple separate insulator components are used to support electrode assembly shape, then shape maintenance is improved, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
By merging the insulating upper portion, side portion, and core portion into a single integrated insulator component, the patent eliminates the need for precise assembly of multiple separate parts. The single component is installed as one unit, significantly reducing assembly precision requirements and manufacturing difficulty while maintaining the electrode assembly shape.
Solution Approach 2:
While the insulator is a single component, it is designed with segmented functional regions (upper, side, and core portions) that each address specific shape maintenance needs. This internal segmentation allows the single component to provide comprehensive shape support without requiring multiple separate external components.
3Reliability
If multiple separate insulator components are used, then insulating performance is improved, but production time and manufacturing cost increase
Solution Approach 1:
The patent merges multiple insulator components into a single integrated component that can be manufactured in one piece and installed as a single unit. This eliminates the need for multiple separate manufacturing processes and assembly steps, significantly improving productivity and reducing manufacturing time while maintaining insulating performance through the integrated design.
Data Source
AI summary
A secondary battery includes: an electrode assembly including: a first electrode plate; a second electrode plate; and a separator between the first electrode plate and the second electrode plate; a case configured to accommodate the electrode assembly; a cap assembly electrically connected to the second electrode plate of the electrode assembly; and an insulator coupled to an upper side of the electrode assembly, wherein the insulator includes: an insulating upper portion configured to cover the upper side of the electrode assembly; an insulating side portion between the case and a side portion of the electrode assembly; and an insulating core portion inserted into a hollow portion of the electrode assembly to support the electrode assembly.