Rechargeable Battery Sealing Member for Terminal Stability
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Solution Overview
Problem
Existing rechargeable batteries face challenges in stabilizing the electrical connection between the terminal post and the cap plate, leading to potential deterioration due to external vibrations or impacts, which can affect the battery's performance and longevity.
Innovation Solution
A sealing member is introduced, formed by insert molding, to cover the terminal post and connection terminal, providing electrical insulation and stable fixation between the terminal and the cap plate, thereby preventing electrical connection deterioration from external factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal post and cap plate are directly connected without additional insulation components, then the device complexity is reduced, but the reliability of electrical connection deteriorates due to potential contact resistance and instability under external vibrations or impacts
Solution Approach 1:
An upper insulation member is introduced as an intermediary component between the terminal post and cap plate. This insulation member provides electrical insulation while maintaining stable electrical connection, resolving the contradiction by adding a mediating element that prevents direct contact between conductive parts and reduces contact resistance without significantly increasing overall device complexity
Solution Approach 2:
The sealing member is formed by insert molding to create a composite structure that integrates multiple functions (sealing, insulation, support) into a single component. This composite approach improves reliability by providing stable electrical connection and protection against external vibrations, while the integrated design minimizes the increase in device complexity
2Reliability
If the sealing member is formed by insert molding to cover the terminal post and connection terminal, then the reliability and resistance to external impacts are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The insert molding process is performed as a preliminary action during assembly, where the sealing member is formed in place to cover the terminal post and connection terminal before final assembly completion. This preliminary formation ensures proper positioning and integration, improving reliability against external impacts while managing manufacturing precision requirements through process integration
Solution Approach 2:
The sealing member integrates multiple functions (sealing, electrical insulation, mechanical support, and vibration resistance) into a single component. This merging of functions improves overall reliability and impact resistance without requiring multiple separate precision components, thereby managing the complexity of manufacturing precision requirements
3Ease of manufacture
If the connection terminal passes through the cap plate without proper insulation, then the ease of manufacture is improved, but harmful electrical contact between the connection terminal and cap plate occurs
Solution Approach 1:
The upper insulation member serves as an intermediary between the connection terminal and cap plate, preventing direct electrical contact while allowing the connection terminal to pass through for manufacturing simplicity. This intermediary layer eliminates the harmful electrical short circuit without complicating the assembly process
Solution Approach 2:
Electrical insulation is applied locally at the critical interface between the connection terminal and cap plate using the upper insulation member, rather than insulating the entire structure. This localized approach prevents harmful electrical contact while maintaining ease of manufacture for the overall assembly
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 sealing member effectively reduces contact resistance and stabilizes the electrode assembly, enhancing the battery's resistance to external impacts and vibrations, thus improving its performance and lifespan.
Implementation Method 1
a sealing member insulating the terminal and the cap plate from each other
Implementation Method 2
the sealing member being formed by insert molding so as to cover the terminal at a terminal hole located at the cap plate
Data Source
AI summary
A rechargeable battery includes an electrode assembly inside a case, a terminal post located entirely outside of, and protruding outwardly from, the case, a connection terminal having a portion that passes through the case, the connection terminal electrically coupling the electrode assembly and the terminal post; and a sealing member enveloping the portion of the connection terminal that passes through the case and electrically insulating the connection terminal from the case.