Secondary Battery Terminal Structure With FRP Insulation
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Solution Overview
Problem
Existing secondary batteries face challenges in ensuring effective electrical insulation and structural integrity, particularly in high-energy density designs, which can lead to short circuits and structural weaknesses.
Innovation Solution
The design incorporates an insulating case and cap plate made of fiber-reinforced plastic (FRP), with specific terminal configurations and connections that include protrusions and bent bodies to ensure electrical insulation and distribute stress, while maintaining a hermetic seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional materials are used for case and cap plate, then manufacturing cost is reduced, but electrical insulation and structural integrity are insufficient
Solution Approach 1:
The patent applies composite materials by using fiber-reinforced plastic (FRP) for the case and cap plate. This composite material provides superior electrical insulation properties and structural integrity compared to conventional materials, directly resolving the contradiction between reliability and manufacturing cost by selecting a material that delivers both performance and cost-effectiveness.
2Strength
If conventional materials are used for case and cap plate, then manufacturing cost is reduced, but structural integrity and stress distribution are insufficient
Solution Approach 1:
The fiber-reinforced plastic (FRP) composite material provides enhanced structural integrity and stress distribution capabilities. The fibrous reinforcement within the plastic matrix creates a material that is both strong and cost-effective, resolving the contradiction between strength and manufacturing cost.
3Reliability
If terminal plates are made larger for better electrical connection, then electrical connection is improved, but device volume increases
Solution Approach 1:
The patent applies parameter changes by optimizing the terminal plate dimensions and material properties. The FRP material allows for thinner, more efficient terminal plate designs that maintain excellent electrical connection through improved conductivity and structural support, thereby achieving reliable electrical connection without increasing device volume.
4Volume of moving object
If case and cap plate are made thinner to reduce volume, then device volume is reduced, but structural integrity deteriorates
Solution Approach 1:
The fiber-reinforced plastic (FRP) composite material enables thinner case and cap plate designs while maintaining structural integrity. The fibrous reinforcement provides exceptional strength-to-weight ratio and structural stability, allowing reduced thickness without compromising strength, thus resolving the contradiction between volume reduction and structural integrity.
Data Source
AI summary
A secondary battery includes an electrode assembly including a first electrode, a second electrode, a separator between the first and second electrodes, a first electrode tab connected to the first electrode, and a second electrode tab connected to the second electrode, a case that accommodates the electrode assembly and includes a top opening exposing an upper surface of the electrode assembly and a bottom opening exposing a lower surface of the electrode assembly, a cap plate combined with the case to cover a portion of the top opening, the cap plate having a conducting hole through which a remaining portion of the top opening of the case is exposed, an upper terminal plate above the cap plate and electrically connected to the first electrode tab through the conducting hole, and a lower terminal plate below the case and electrically connected to the second electrode tab through the bottom opening.