Secondary Battery Lead Member Gap Prevention via Layered Insulation
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Solution Overview
Problem
Conventional lead members for secondary batteries often experience gaps between the conductor and insulating films, leading to potential electrolyte leakage and reduced production efficiency, especially when the conductor is thickened for improved heat radiation.
Innovation Solution
A lead member configuration featuring a conductor with insulating films having inner and outer layers, where the inner layers are welded together with additional insulators on the side surfaces to minimize gaps, using a method that involves preparing the conductor and insulating films, placing additional insulating materials, and performing a hot press process at controlled temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the conductor is thickened for improved heat radiation, then heat dissipation performance is improved, but gaps between the conductor and insulating films occur leading to electrolyte leakage
Solution Approach 1:
The insulating film is divided into multiple layers: an inner layer directly bonded to the conductor and outer layers providing additional insulation. This segmented structure ensures complete coverage of the thickened conductor without gaps, preventing electrolyte leakage while maintaining heat radiation performance
Solution Approach 2:
Multiple insulating film layers with different properties are combined to create a composite insulation structure. The inner layer provides direct adhesion to the conductor, while outer layers provide enhanced insulation, collectively preventing electrolyte contact with the thickened conductor surface
2Device complexity
If conventional insulating films are used without additional insulators, then device complexity is reduced, but gaps form between insulating films and conductor reducing reliability
Solution Approach 1:
Additional insulators are placed on the conductor surface before the insulating films are applied. This preliminary action ensures that the subsequent insulating films bond to a prepared surface, preventing gap formation between the films and conductor while maintaining a manageable device structure
3Manufacturing precision
If extreme processing conditions are used to prevent gaps, then manufacturing precision is improved, but production efficiency decreases
Solution Approach 1:
The bonding parameters of the insulating films are optimized to achieve complete coverage and adhesion under moderate processing conditions. By adjusting film composition, thickness, and bonding conditions, high manufacturing precision is achieved without requiring extreme processing conditions, thereby maintaining production efficiency
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
Significantly reduces the occurrence of gaps between the conductor and insulating films, enhancing the reliability of secondary battery packages by preventing electrolyte leakage and improving production efficiency without the need for extreme processing conditions.
Implementation Method 1
a step of welding the first insulating film and the second insulating film to each other on a first surface side and on a second surface side
Implementation Method 2
performing a hot press process at controlled temperatures and pressures
Data Source
AI summary
A lead member for a secondary battery includes a conductor, and a covering material. The conductor has an upper surface and a lower surface that extend in a length direction and a width direction and are opposite to each other, and a first side surface and a second side surface that extend in the length direction and a thickness direction, connect the upper surface to the lower surface, and are opposite to each other. The covering material is formed by sticking a plurality of insulating films together to surround the upper surface, the first side surface, the lower surface, and the second side surface. Each of the plurality of insulating films includes an inner layer and an outer layer, in an order from a side closer to the conductor. The lead member includes a first insulator and a second insulator on the first side surface and the second side surface of the conductor respectively, in an area surrounded by the covering material of the conductor. The first insulator and the second insulator have a lower melting point than the inner layer. The first insulator and the second insulator are placed to be separated from each other.