Button Cell Cap Assembly for Reverse Insertion Prevention
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Solution Overview
Problem
Existing rechargeable batteries face challenges in achieving high energy density while being ultra-small, and they lack effective mechanisms to prevent reverse direction insertion and external short circuits.
Innovation Solution
The design incorporates a cap assembly with a cap plate and terminal plate that are thermally fused and electrically insulated, along with a direction determining member that covers the cap plate and is coupled to the case, forming an extended part to prevent reverse insertion and external short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery size is reduced to achieve ultra-small form factor, then the volume decreases, but the energy density becomes insufficient
Solution Approach 1:
The battery is divided into distinct functional segments: a case assembly containing the electrode assembly, and a separate cap assembly with cap plate and terminal plate. This segmentation allows optimization of each component's function while maintaining compact overall dimensions, enabling ultra-small form factor without compromising energy density.
Solution Approach 2:
The electrode assembly is nested within the case, and the terminal plate is nested within the cap assembly structure. The directional determining member is positioned within the cap assembly to define orientation. This nested arrangement maximizes space utilization in the ultra-small battery, allowing high energy density while maintaining compact volume.
2Stability of the object's composition
If the cap plate and terminal plate are thermally fused, then the structural stability improves, but the manufacturing precision requirements increase
Solution Approach 1:
The thermal fusion is applied locally at specific bonding regions between the cap plate and terminal plate, rather than requiring uniform precision across the entire assembly. This localized approach maintains structural stability while reducing overall manufacturing precision requirements.
3Reliability
If the direction determining member covers the cap plate, then the prevention of reverse insertion improves, but the device complexity increases
Solution Approach 1:
The direction determining member creates an asymmetric configuration on the cap assembly, with the extended part protruding in a specific direction. This asymmetry provides mechanical prevention of reverse insertion without requiring complex control systems or multiple components, thus improving reliability while minimizing added complexity.
4Reliability
If the extended part is formed to prevent reverse insertion, then the reliability improves, but the ease of operation decreases
Solution Approach 1:
The extended part of the direction determining member is designed to preliminarily prevent reverse insertion by creating mechanical interference before actual insertion occurs. The asymmetric geometry provides inherent guidance that prevents incorrect orientation, ensuring reliable operation while maintaining ease of correct insertion through intuitive alignment.
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 configuration effectively prevents reverse direction insertion and external short circuits, while also improving structural stability and safety against physical impacts, such as in drop tests and tumbling tests.
Implementation Method 1
a terminal plate coupled to the cap plate; wherein the cap plate and the terminal plate are thermally fused with a thermal fusion member therebetween
Data Source
AI summary
A rechargeable battery includes: a case accommodating an electrode assembly and having an opening; a cap assembly including a cap plate coupled to the case to cover the opening, and a terminal plate coupled to the cap plate; and a direction determining member covering the cap plate and coupled to the case to define an extended part.