Secondary Battery Spacer Structure for Insulated Cap Coupling
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Solution Overview
Problem
Existing secondary batteries face challenges in ensuring secure electrical connections and preventing short circuits while maintaining ease of assembly and durability.
Innovation Solution
The design incorporates a spacer with protrusions that elastically deform to facilitate secure coupling with the case, providing electrical insulation and preventing short circuits, while allowing easy assembly by interference fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spacer with protrusions is used to secure the cap assembly to the case, then electrical insulation and short circuit prevention are improved, but assembly complexity increases
Solution Approach 1:
The spacer acts as an intermediary component between the cap assembly and the case. It provides electrical insulation to prevent short circuits while mechanically securing the cap assembly through interference fitting with the case groove, thus improving reliability without significantly increasing assembly complexity
Solution Approach 2:
The electrical insulation function is extracted from the cap assembly itself and placed into a separate spacer component. This allows the cap assembly to focus on its primary sealing and electrical connection functions while the spacer handles insulation and mechanical retention
2Strength
If protrusions are designed to elastically deform for interference fitting, then secure coupling is improved, but manufacturing precision requirements increase
Solution Approach 1:
The protrusions are designed with elastic deformation capability, allowing them to temporarily change shape during assembly (compressing to pass through the groove) and then recover to provide secure coupling. This parameter change approach reduces the need for extremely tight dimensional tolerances while maintaining strong coupling
3Stability of the object's composition
If the spacer includes multiple protrusions spaced apart, then contact stability with the case is improved, but device complexity increases
Solution Approach 1:
The single continuous spacer structure is segmented into multiple discrete protrusions spaced around its circumference. Each protrusion independently contacts the case, providing distributed stability and preventing rotation or misalignment while maintaining a relatively simple overall spacer design
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 solution ensures secure electrical connections, prevents short circuits, and simplifies the manufacturing process of secondary batteries.
Implementation Method 1
the spacer may include an elastic material. while the spacer is coupled to an outer portion of the case, the first protrusion and the second protrusion may be elastically deformed in a direction away from each other
Data Source
AI summary
A secondary battery includes an electrode assembly including a first electrode and a second electrode, a case including a first side that is open, the case accommodating the electrode assembly and being electrically connected to the second electrode, a cap assembly coupled to the first side of the case, the cap assembly being electrically connected to the first electrode, and a spacer coupled to an outer portion of the case and contacting the cap assembly, the spacer including a first protrusion and a second protrusion opposite the first protrusion, the first protrusion and the second protrusion contacting the case.