Cylindrical Battery Terminal Layout With Conductive Washer Insulation
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Solution Overview
Problem
Existing cylindrical secondary batteries require complex electrical connection structures due to opposite positioning of positive and negative electrode terminals, complicating assembly and increasing component count for insulation and waterproofing.
Innovation Solution
A secondary battery design with a conductive washer and insulative washer configuration that allows for unidirectional placement of positive and negative electrode terminals, enabling a simplified electrical connection structure and reduced electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of batteries are assembled together to form a battery pack, then the output of the battery pack increases, but the temperature distribution becomes non-uniform and hot spots are generated
Solution Approach 1:
The battery pack is divided into multiple battery modules, each with its own cooling channel. This segmentation allows for localized temperature control and prevents hot spots by distributing the thermal management load across multiple smaller units rather than using a single centralized cooling system.
Solution Approach 2:
A cooling plate with cooling channels is introduced as an intermediary component between the batteries and the cooling fluid. This cooling plate acts as a heat transfer mediator, efficiently conducting heat away from the batteries and distributing it through the cooling fluid flow, thereby maintaining uniform temperature distribution across the battery pack.
2Reliability
If cooling channels are formed in a cooling plate for a battery pack, then cooling efficiency improves, but the cooling plate requires punching processes that reduce manufacturing precision
Solution Approach 1:
The traditional mechanical punching process for creating cooling channels is replaced with a molding process. The cooling channels are directly formed during the molding of the cooling plate, eliminating the need for subsequent punching operations. This substitution of manufacturing methods preserves the structural integrity and dimensional precision of the cooling plate while still achieving effective cooling channels.
3Ease of manufacture
If the anode active material layer is formed first and then the cathode active material layer is formed, then the manufacturing process follows conventional steps, but the anode expands during charging causing defects
Solution Approach 1:
The cathode active material layer is formed in advance on the current collector before the anode active material layer is applied. This preliminary formation of the cathode layer ensures that when the anode expands during subsequent charging cycles, it does so against a pre-established cathode structure, preventing defects such as delamination or short circuits that would occur if the cathode were formed after the anode.
Solution Approach 2:
The conventional sequence of forming the anode layer first and then the cathode layer is inverted. Instead of the traditional anode-first approach, the patent applies the cathode active material layer first, followed by the anode active material layer. This inversion addresses the expansion issue by establishing the cathode structure before the anode's volume changes occur during charging.
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
This design facilitates stable, low-resistance connections between batteries, enhancing energy density and simplifying the assembly process while maintaining structural integrity.
Implementation Method 1
a cooling plate, having cooling channels formed therein, is disposed between the lower ends of the battery modules
Implementation Method 2
cooling channels through which a cooling fluid flows are formed in the cooling plate
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
The present invention provides a secondary battery including an electrode assembly having a first electrode tab and a second electrode tab, a battery can electrically connected to the second electrode tab and having an opening portion configured to accommodate the electrode assembly, a top cap configured to cover the opening portion of the battery can and electrically connected to the first electrode tab, a gasket provided between the battery can and the top cap, a conductive washer electrically connected to the battery can and configured to adjoin at least a part of a peripheral portion of the opening portion, an insulative washer provided between the top cap and the conductive washer and configured to electrically insulate the top cap and the conductive washer, and a fixing member provided between the conductive washer and the insulative washer.