Battery Cell Insulation Structure for Tab-to-Casing Isolation
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Solution Overview
Problem
Batteries are prone to insulation failure due to structural limitations of the cell and tab portions within the battery casing, leading to potential electrical connections and safety risks.
Innovation Solution
A battery design incorporating a first and second insulating film, where the second film is independent from the first and covers the tab portions, ensuring reliable insulation by covering the cell body and tab portions, thereby improving assembly efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single insulating film is used to cover the cell body, then the insulation structure is simple, but the tab portions are exposed and insulation failure risk increases
Solution Approach 1:
The insulating film is divided into two independent segments: a first insulating film covering the cell body and a second insulating film covering the tab portions. This segmentation allows each film to be optimized for its specific function and position, ensuring complete insulation coverage while maintaining structural simplicity.
Solution Approach 2:
The second insulating film acts as an intermediary element that specifically protects the tab portions, which are the critical connection points between the cell and external circuitry. By adding this intermediate insulating layer, the patent eliminates the insulation gap without significantly increasing overall complexity.
2Ease of manufacture
If the second insulating film is integrated with the first insulating film, then the assembly process is simplified, but the insulation stability at the connection point decreases
Solution Approach 1:
The insulating films are kept as separate, independent components rather than being integrated into a single piece. This segmentation allows each film to be independently positioned and secured, ensuring stable insulation at the connection point while maintaining ease of assembly through modular installation.
Solution Approach 2:
Each insulating film is designed with specific local properties suited to its function: the first film covers the cell body surface while the second film specifically protects the tab portions. This local differentiation ensures optimal insulation stability at each critical location without requiring complex integration.
3Productivity
If insulating films are not used, then the assembly process is fastest and structure is simplest, but insulation failure and safety risks occur
Solution Approach 1:
The insulating films are pre-positioned on the cell body and tab portions before final assembly into the battery casing. This preliminary action ensures insulation is already in place, preventing insulation failures during subsequent assembly steps while maintaining high productivity through streamlined positioning.
Solution Approach 2:
Thin insulating films are used to provide effective electrical insulation without adding significant bulk or complexity to the assembly process. These flexible films can be easily positioned and conform to the cell surfaces, ensuring complete coverage while maintaining assembly efficiency.
Data Source
AI summary
A battery and a battery manufacturing method are provided. The battery includes a battery casing, a cell, a first insulating film, and a second insulating film. The cell is disposed in the battery casing and includes a cell body and a tab portion, and the tab portion extends from a side surface of the cell body. The first insulating film covers at least a portion of the cell body. The second insulating film is independent from the first insulating film. The second insulating film covers an upper surface of the first insulating film and covers at least a portion of the tab portion, and the first insulating film is located between the cell body and the second insulating film.