Battery Spacer Absorbs Vibration to Prevent Lead Tab Contact Failure
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Solution Overview
Problem
High power rechargeable batteries, especially those used in vehicles, face issues with contact failure between lead tabs and electrode assemblies due to external vibrations and impacts, leading to increased resistance, heat generation, and potential explosion or ignition, as well as terminal deformation or breakage.
Innovation Solution
Incorporating a spacer made of elastic polymer material between the lead tab and the case, which absorbs external impacts and vibrations, providing support to the electrode assembly and terminals, and featuring a design with support parts and a connecting bar to stabilize the terminal connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead tab is directly connected to the electrode assembly without insulation support, then the electrical connection is simple, but the contact becomes bad under external vibration or impact
Solution Approach 1:
An insulating member is introduced as an intermediary component between the lead tab and the electrode assembly. This insulating member includes a groove that receives and secures the lead tab, providing mechanical support and stable positioning without compromising electrical insulation. The intermediary structure resolves the contradiction by adding reliability through the groove-based securing mechanism while maintaining relatively simple overall device complexity.
2Strength
If the electrode assembly is suspended to the lead tab without insulation, then the structure is simple, but the terminal may be deformed or cut under external vibration or impact
Solution Approach 1:
The insulating member serves as a mediator between the electrode assembly and the lead tab/terminal assembly. It provides a structured interface with grooves that secure the lead tab and positioning features that support the electrode assembly, thereby strengthening the terminal connection against vibration and impact while adding only moderate structural complexity.
Solution Approach 2:
The insulating member is formed as a thin-walled structure with integrated grooves and positioning features. This thin-film approach provides the necessary mechanical support and terminal protection without adding excessive structural complexity or weight to the battery assembly.
3Reliability
If insulation sheets are placed between lead tab and case, then insulation is improved, but the lead tab shaking under vibration is not prevented
Solution Approach 1:
The insulating member is positioned as an intermediary between the lead tab and the electrode assembly, with grooves that actively secure the lead tab. This goes beyond simple insulation sheets by providing both electrical insulation and mechanical stabilization through the groove-based securing mechanism, preventing lead tab shaking under vibration.
4Strength
If supports surround the lead connectors, then impact protection is improved, but the structure becomes more complex
Solution Approach 1:
The insulating member merges multiple functions into a single integrated component: it provides electrical insulation between conductive parts, mechanical support through grooves that secure the lead tab, and impact resistance through its structural design. This merging approach improves impact resistance while avoiding the complexity of separate support structures.
Solution Approach 2:
The insulating member is designed as a multi-functional component that simultaneously provides insulation, mechanical support, vibration damping, and impact protection. This universal approach consolidates multiple protective functions into one element, improving impact resistance without proportionally increasing device complexity.
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 spacer effectively absorbs external impacts and vibrations, preventing contact failure and terminal deformation, thereby enhancing the durability and safety of the rechargeable battery by maintaining stable electrical connections and preventing overheating or explosion.
Implementation Method 1
a vibration-proof member 60 made of a polymer having elasticity to absorb an external impact
Data Source
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AI summary
A rechargeable battery that improves a vibration-proof property is provided. The rechargeable battery includes: an electrode assembly including a positive electrode, a negative electrode, and a separator that is disposed between the positive electrode and the negative electrode, a case that houses the electrode assembly, and a cap assembly including terminals that are coupled to the case and that are electrically connected to the electrode assembly, wherein the terminal has a lead tab that is electrically connected to the electrode assembly and a spacer is installed between the lead tab and the case.