Battery Cell Pouch Insulator for Short-Circuit Isolation
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Solution Overview
Problem
Existing battery designs face challenges in preventing short circuits between active battery components and the housing, which can reduce the battery's ability to charge, discharge, or store energy effectively, due to inadequate insulation and leakage of electrolyte solutions.
Innovation Solution
A flexible pouch insulator made of polymeric material is inserted into the battery housing, fixed around the top portion, and provides a seamless layer of insulation between the active battery components and the housing, allowing for the absorption of electrolyte solutions and enhancing dielectric properties, while minimizing the risk of leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid insulator is used to prevent short circuits between active battery components and housing, then insulation reliability is improved, but the insulator cannot accommodate expansion or contraction of battery components during charging and discharging
Solution Approach 1:
The patent employs a flexible pouch insulator made of polymeric material that can expand and contract to accommodate the swelling and shrinking of battery components during charge-discharge cycles. This flexible film structure maintains reliable insulation while adapting to dimensional changes, resolving the contradiction between insulation reliability and adaptability to expansion.
2Reliability
If active battery components are wrapped in insulating tape to prevent contact with housing, then short circuit prevention is improved, but the absorption of electrolyte solution is reduced
Solution Approach 1:
The patent extracts the insulating function from the battery components themselves and places it in a separate pouch insulator structure. This allows the battery components to remain unwrapped and fully absorb electrolyte solution, while the separate pouch provides the necessary insulation barrier, thus resolving the contradiction between short circuit prevention and electrolyte absorption.
3Reliability
If a seamless pouch insulator is used to prevent electrolyte leakage, then leakage risk is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent uses a seamless flexible pouch structure that eliminates seams and joints where electrolyte leakage could occur. The seamless design, achieved through advanced forming processes, provides superior leakage prevention despite increased manufacturing complexity, resolving the contradiction between reliability and ease of manufacture.
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
The insulator effectively prevents short circuits, improves energy storage and charging capabilities, and reduces the likelihood of electrolyte leakage, thereby enhancing the overall performance and safety of the battery cell.
Implementation Method 1
The flexible material can flex when an active battery component is inserted into the insulator, e.g., the insulator can expand or contract around the active battery component within the housing
Implementation Method 2
The insulator can provide dielectric advantages relative to a battery that does not have this insulator. For example, there can be an air gap between the insulator and the housing. This air gap can provide additional insulation between the active battery component and the housing
Implementation Method 3
when an electrolyte solution is added to the battery cell (e.g., poured or injected into the battery cell and into the pouch), the active battery component can absorb the electrolyte solution
Data Source
AI summary
Disclosed are systems and methods for a device. The device can include a battery housing comprising a first lateral wall and a second lateral wall. The device can include an insulator disposed within the battery housing between the battery housing and an active battery component. A portion of the insulator can be fixed to an inner surface of the first lateral wall and the portion of the insulator fixed to an inner surface of the second lateral wall.