Rechargeable Battery Terminal Plate Venting Against Short Circuits
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Solution Overview
Problem
Ultra-small rechargeable batteries used in wearable devices are prone to short circuits, terminal damage, and explosion risks due to assembly errors and unintended pressure, especially with small electrode terminals.
Innovation Solution
A rechargeable battery design featuring a terminal plate with a protrusion and a flange portion, which includes a protrusion with a curved surface and an inclined surface, and a thermal-fusion layer to insulation-bond the cap and flange portions, allowing for dispersion of stress and formation of a ventilation channel to prevent short circuits, terminal damage, and explosions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electrode terminals are made small to reduce battery size, then the battery can be used in wearable devices, but short circuits may occur between electrode terminals due to assembly errors
Solution Approach 1:
The terminal plate is segmented into a flat plate portion and a protruding protrusion portion, creating spatial separation between the electrode terminal connection area and the cap plate contact area. This segmentation prevents short circuits by ensuring that even if assembly occurs in an inverted state, the protrusion geometry prevents direct contact between opposite polarity terminals.
Solution Approach 2:
The terminal plate employs an asymmetric design where the protrusion extends in a specific direction with a predetermined height, creating a geometric configuration that is not symmetrical. This asymmetry ensures that assembly can only occur in the correct orientation, as the protrusion will not align properly with the cap plate if inverted, thereby preventing short circuits from assembly errors.
2Volume of moving object
If the electrode terminals are made small to reduce battery size, then the battery can be used in wearable devices, but damage to electrode terminals due to pressure may occur
Solution Approach 1:
The protrusion design provides beforehand cushioning by creating a geometric buffer zone. The protruding portion with predetermined height acts as a protective element that absorbs and distributes external pressure before it reaches the electrode terminal connection area, preventing damage to the small electrode terminals while maintaining the compact battery size.
3Reliability
If the battery is sealed to prevent leakage, then battery reliability is improved, but explosion risk increases if temperature and pressure increase inside the battery
Solution Approach 1:
The cap plate is segmented into a plate portion and a protrusion portion with different functions. The plate portion provides sealing to prevent leakage, while the protrusion portion creates a controlled venting pathway. This segmentation allows the battery to maintain reliability through sealing while simultaneously providing a safety mechanism to release excessive pressure and temperature, preventing explosions.
4Productivity
If assembly is simplified to reduce manufacturing complexity, then productivity increases, but assembly errors between cap plate and terminal plate increase
Solution Approach 1:
The asymmetric protrusion design on the terminal plate creates a self-aligning feature that guides the cap plate into the correct position during assembly. This geometric constraint reduces assembly errors by making incorrect assembly physically impossible, while maintaining simple manufacturing processes. The asymmetry provides built-in error prevention without requiring complex assembly procedures.
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 design effectively suppresses short circuits, terminal damage, and explosion risks by dispersing assembly errors and unintended pressure, ensuring safety and reliability in the rechargeable battery.
Implementation Method 1
The thermal-fusion layer may melt at a predetermined temperature exceeding a temperature for curing the thermal-fusion layer.
Data Source
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AI summary
A rechargeable battery includes: an electrode assembly including a first electrode, a second electrode, and a separator between the first electrode and the second electrode; a case configured to be connected to the first electrode to accommodate the electrode assembly, and including an opening to receive the electrode assembly; a cap plate configured to be coupled with the case to cover an outer area of the opening, and including a through-hole to expose a central area of the opening; and a terminal plate configured to be connected to the second electrode and to be insulation-bonded to the cap plate, and including a flange portion covering the through-hole, and a protrusion penetrating the through-hole from the flange portion.