Secondary Battery Top Cover Insulation for Crush Protection
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Solution Overview
Problem
The contact area between the lower plastic member and the cell body in secondary batteries is relatively small, leading to high pressure on the cell body under vibration or inversion conditions, which can cause crush damage and affect performance and safety.
Innovation Solution
The secondary battery design includes an insulating member that increases the contact area between the cell body and other components by attaching the insulating member to the lower plastic member, using a snap-fit structure for positioning and fixation, and optimizing the contact area ratios to ensure adequate insulation and current-carrying capacity while preventing crush damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the lower plastic member directly contacts the cell body with a small contact area, then the structural simplicity is maintained, but the pressure on the cell body increases under vibration or inversion conditions causing crush damage
Solution Approach 1:
An insulating member is introduced as an intermediary component between the lower plastic member and the cell body. This insulating member has a larger contact area with the cell body than the lower plastic member alone, thereby distributing the pressure and preventing crush damage while maintaining structural simplicity through the integration of this intermediary element.
2Object-affected harmful factors
If the contact area between the lower plastic member and the cell body is increased, then the pressure distribution is improved, but the device complexity increases due to additional components
Solution Approach 1:
The insulating member is merged with the lower plastic member assembly, where the insulating member serves dual purposes: it provides electrical insulation and simultaneously increases the contact area with the cell body. This merging approach improves pressure distribution without significantly increasing device complexity, as the insulating member is an integrated part of the overall structure rather than a separate additive component.
3Object-affected harmful factors
If the insulating member is attached to the lower plastic member, then the contact area is increased to reduce pressure, but the manufacturing precision requirements increase to ensure proper positioning
Solution Approach 1:
The insulating member is designed with pre-formed positioning structures such as protrusions or recesses that align with corresponding features on the lower plastic member or cell body. This preliminary action of incorporating positioning features during the insulating member's fabrication ensures accurate positioning during assembly, reducing the need for high-precision adjustment operations and thereby lowering manufacturing precision requirements while still achieving the pressure reduction goal.
Data Source
AI summary
A secondary battery includes an electrode assembly and a top cover assembly, the electrode assembly includes a cell body and an insulating member, and the top cover assembly includes a lower plastic member. The insulating member is provided on the lower plastic member and in contact with the cell body, to increase a contact area between the cell body and other components, and reduce the pressure imposed on the cell body under conditions such as vibration. A side of the lower plastic member near the insulating member is provided with a positioning step and the insulating member can be mated to the positioning step, to form a relative positioning between the lower plastic member and the insulating member.