Cylindrical Battery Integrated Assembly Injection Molding
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Solution Overview
Problem
Cylindrical secondary batteries face increased internal resistance and manufacturing complexity due to separate processes for the gasket, center pin, and insulation plate, which can lead to damage and safety issues from vibrations and impacts.
Innovation Solution
An integrated assembly combining a gasket, insulation plate, and central pin, formed by injection molding, is used to securely house the electrode assembly and cap assembly, preventing movement and deformation, and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate processes are used for gasket, center pin, and insulation plate, then manufacturing flexibility is maintained, but manufacturing complexity increases and time is extended
Solution Approach 1:
The patent combines the gasket, center pin, and insulation plate into a single integrated assembly that is injection molded as one piece. This eliminates the need for separate manufacturing processes and assembly steps, reducing manufacturing complexity while maintaining design flexibility. The integrated structure allows all three components to be produced simultaneously in a single molding cycle.
2Manufacturing precision
If separate processes are used for gasket, center pin, and insulation plate, then individual component optimization is possible, but manufacturing time increases
Solution Approach 1:
By integrating three separately manufactured components into one injection-molded piece, the patent eliminates multiple manufacturing cycles and assembly operations. The single-shot or multi-cavity injection molding process produces the entire assembly in one operation, significantly reducing manufacturing time while maintaining precise dimensional control through mold design.
3Adaptability or versatility
If center pin is separate from electrode assembly, then assembly flexibility is maintained, but internal resistance increases due to movement and vibrations
Solution Approach 1:
The integrated assembly permanently bonds the center pin to the electrode assembly through injection molding, eliminating relative movement between these components. This fixed connection prevents vibrations and movements that would increase internal resistance, while the modular integrated assembly can still be installed as a unit, maintaining assembly flexibility at the system level.
4Ease of repair
If center pin is separate from electrode assembly, then replacement is easier, but damage to cap assembly from separation during impact occurs
Solution Approach 1:
By integrating the center pin with the electrode assembly and gasket, the patent creates a unified structure that prevents the center pin from separating from the electrode assembly during impacts or drops. The injection-molded connection ensures the center pin remains firmly attached, eliminating the risk of pin separation and subsequent cap assembly damage, while the entire integrated assembly can be replaced as a single unit if needed.
Data Source
AI summary
A cylindrical secondary battery including: an electrode assembly including first and second electrode tabs; a can to house the electrode assembly; a cap assembly to seal an opening of the can; and an integrated assembly including a gasket, an insulation plate, and a central pin. An outer edge of the gasket is bent by the can, around an outer edge of the cap assembly. The insulation plate extends from the gasket, to cover a surface of the electrode assembly. The central pin extends from the center of the insulation plate, into the electrode assembly.