Battery Internal Short-Circuit Structure for Low-Voltage Failure Simulation
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Solution Overview
Problem
Existing methods struggle to accurately reproduce the low-voltage mode of internal short-circuits in secondary batteries, which often occur due to separator damage, making safety evaluations unreliable.
Innovation Solution
An internal short-circuit device is developed with an insulating member and insulating layer, allowing a short-circuit inducing portion of an electrode plate to pass through a hole, enabling precise control of short-circuit resistance and location, and reproducing various internal short-circuit modes without external deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an additional metal layer is inserted to reduce short-circuit resistance and induce ignition, then the ability to trigger thermal runaway is improved, but the ability to reproduce low-voltage mode short-circuits caused by separator damage is worsened
Solution Approach 1:
The patent introduces an insulating layer as an intermediary component between the first and second electrode plates. This insulating layer can be selectively removed or damaged to create controlled short-circuit paths that accurately reproduce separator failure modes. The insulating layer serves as a mediator that enables both reliable short-circuit induction and accurate reproduction of low-voltage mode failures, resolving the contradiction between safety evaluation reliability and short-circuit mode reproduction accuracy.
Solution Approach 2:
The patent segments the short-circuit induction mechanism into multiple functional components: an insulating member with a hole, an insulating layer, and electrode plates with specific configurations. This segmentation allows independent optimization of each component - the insulating layer can be designed to fail at specific locations and conditions, enabling accurate reproduction of separator damage scenarios while maintaining reliable short-circuit induction capability.
2Reliability
If conventional methods are used to induce internal short-circuits, then short-circuit resistance is reduced, but the temperature required to induce short-circuit is excessively high and external deformation is required
Solution Approach 1:
The patent applies preliminary action by pre-configuring the insulating layer and insulating member structure before testing. The insulating layer is positioned and secured in advance, allowing the short-circuit path to be established through controlled removal or degradation of this pre-positioned component. This eliminates the need for high-temperature induction and external deformation during actual short-circuit events, as the pathway is already prepared.
Solution Approach 2:
The patent replaces the mechanical/thermal system required for conventional short-circuit induction (high temperature and external deformation) with an electrochemical system. The insulating layer can be removed or degraded through electrochemical processes at normal operating temperatures, enabling short-circuit induction without excessive heat or mechanical deformation.
3Adaptability or versatility
If safety devices are evaluated using existing methods, then some safety aspects are covered, but the reproducibility and accuracy of low-voltage mode short-circuit evaluation is worsened
Solution Approach 1:
The patent applies local quality by creating a localized short-circuit path through the insulating layer configuration. The insulating layer is positioned at specific locations between electrode plates, allowing precise control over where short-circuits occur. This localized approach enables accurate measurement of short-circuit resistance and voltage changes at specific points, improving measurement precision while maintaining versatile safety evaluation coverage through configurable insulating layer positions.
Data Source
AI summary
An internal short-circuit device includes an insulating member including a hole, a short-circuit inducing portion of a first electrode plate of a battery extending through the hole in the insulating member, and an insulating layer disposed between the insulating member and a second electrode plate of the battery. A first surface of the insulating layer is in contact with the short-circuit inducing portion of the first electrode plate, and a second surface of the insulating layer, which is opposite to the first surface, is in contact with the second electrode plate.