Rechargeable Battery Terminal Cap Insulation Design
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Solution Overview
Problem
Rechargeable batteries and battery modules face the challenge of preventing external short-circuits of electrode terminals, which can occur during distribution, transportation, or use in applications like hybrid electric vehicles.
Innovation Solution
The use of terminal caps made from electrical insulating materials such as synthetic resin or silicone, which cover the electrode terminals and bus bars, providing a secure and insulating cover to prevent short-circuits. These caps include features like through-holes, coupling holes, expanding holes, and cut-out regions to ensure a secure fit and facilitate measurement of open circuit voltage without detaching from the terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrode terminals are exposed to the outside of the case for electrical connection, then ease of operation is improved, but reliability deteriorates due to risk of external short-circuit
Solution Approach 1:
An insulating structure is introduced as an intermediary element between the electrode terminal and the external environment. This insulating structure includes an insulating case portion that surrounds the electrode terminal and an insulating film that covers the terminal hole, preventing direct contact between the terminal and conductive objects while allowing electrical connections to be made through the insulating structure.
2Reliability
If insulating structure is added around electrode terminal, then reliability is improved by preventing short-circuit, but device complexity increases
Solution Approach 1:
The insulating structure is merged with the existing case structure. The insulating case portion is integrated into the case body, and the insulating film is applied to the terminal hole area, combining the protective function with the existing structural elements rather than adding completely separate components.
Solution Approach 2:
The insulating structure serves multiple functions simultaneously: it provides electrical insulation to prevent short-circuits, maintains structural integrity of the case, and facilitates the connection process by providing a defined interface for terminal access.
3Reliability
If electrode terminal is covered with insulating material, then reliability is improved by preventing short-circuit, but ease of operation deteriorates due to reduced accessibility
Solution Approach 1:
The insulating structure is segmented to create specific access points. The insulating case portion has a terminal hole that provides access to the electrode terminal, and the insulating film has an opening at the terminal hole, allowing electrical measurements and connections to be made through these openings without compromising the overall insulation.
Data Source
AI summary
A rechargeable battery and a battery module, the rechargeable battery including an electrode assembly formed by winding a positive electrode and a negative electrode and a separator therebetween; a case accommodating the electrode assembly; a cap plate sealing an opening at one side of the case, the cap plate including a terminal hole therethrough; an electrode terminal in the terminal hole of the cap plate, the electrode terminal extending to an outside from an inside of the case and being connected to the electrode assembly; and a terminal cap including an electrical insulating material, the terminal cap covering the electrode terminal from the outside of the case.