Battery Pack Lead Plate Insulation Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs are prone to short-circuits due to water or foreign matter entering and causing electrical contact between adjacent lead plates, as the insulating sheets used to prevent this often peel off at the gaps between plates, leading to potential short-circuits.
Innovation Solution
A battery pack design where only one lead plate is partially covered by an electric insulation sheet, increasing the separation distance between exposed portions of lead plates and reducing the likelihood of short-circuits, while also adhering the insulation sheet to the battery cell case to enhance durability and prevent peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one insulating sheet is adhered to all lead plates on one side of the battery cells, then the protection against short-circuit is improved, but the insulating sheet peels off at the gaps between adjacent lead plates
Solution Approach 1:
The patent divides the insulating protection into separate segments: one insulating sheet is dedicated to each individual lead plate rather than using a single continuous sheet across multiple plates. This segmentation prevents the sheet from peeling at gaps between plates, as each sheet is confined to its own plate surface where adhesion is maintained.
Solution Approach 2:
The patent extracts the insulating sheet from the gap regions between lead plates and confines it only to the surfaces of individual lead plates. By removing the sheet from areas where peeling occurs (the gaps), the design eliminates the adhesion problem while maintaining protection where needed.
2Reliability
If one insulating sheet straddles the gaps between adjacent lead plates, then coverage is improved, but water or foreign matter can create electrical connection when the sheet peels off
Solution Approach 1:
By segmenting the insulating sheets so that each plate has its own dedicated sheet rather than sharing a continuous sheet across gaps, the patent ensures that each sheet remains firmly adhered to its respective plate surface, preventing peeling that would expose lead plates to water and foreign matter.
Solution Approach 2:
The patent applies insulating sheets preliminarily and specifically only on the surfaces of individual lead plates before assembly, ensuring that the sheets are positioned to provide protection without extending into gap areas where they would be susceptible to peeling and subsequent harmful contact.
3Reliability
If insulation sheets cover all lead plates, then short-circuit prevention is improved, but the amount of insulation material increases
Solution Approach 1:
The patent applies insulating sheets locally only on the surfaces of individual lead plates rather than using a continuous sheet across all plates and gaps. This localized application provides sufficient insulation protection exactly where needed on each plate surface while minimizing the total quantity of insulating material required.
Data Source
AI summary
A battery pack includes a battery cell case, a plurality of battery cells accommodated in the battery cell case, a plurality of lead plates connected to the battery cells, arranged on a same side surface of the battery cell case, and arranged to be separated from each other, and one or more insulation sheets. A first insulation sheet included in the one or more insulation sheets is adhered to a surface of a first lead plate so as to cover the first lead plate at least partially and not to cover lead plates other than the first lead plate.