Button Cell Cap-Terminal Insulation to Prevent Short Circuits
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Solution Overview
Problem
Conventional button cells often experience short circuits between the cap plate and terminal plate during manufacturing, transportation, or use, which affects their reliability and performance in wearable devices.
Innovation Solution
A button cell design that includes an insulating structure between the cap plate and terminal plate, utilizing a bonding layer to insulate and bond them, and an insulating structure with distinct material properties to prevent short circuits, ensuring reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cap plate and terminal plate are bonded directly without additional insulating structures, then the device complexity is reduced and manufacturing is simplified, but short circuits occur between the cap plate and terminal plate during manufacturing, transportation, or use
Solution Approach 1:
An insulating structure is introduced as an intermediary component between the cap plate and terminal plate. This insulating structure includes an insulating layer that contacts both the cap plate and terminal plate, creating a reliable electrical isolation barrier without requiring complex multi-layer constructions or additional fastening mechanisms.
Solution Approach 2:
The insulating structure is segmented into functional portions: a first portion contacting the cap plate, a second portion contacting the terminal plate, and optionally a third portion extending between them. This segmentation allows each portion to be optimized for its specific function while maintaining overall simplicity.
2Reliability
If the insulating structure uses the same material as the bonding layer, then manufacturing is simplified and material inventory is reduced, but the insulating effectiveness is compromised and short circuits may occur
Solution Approach 1:
The insulating structure uses a material that is specifically selected for its insulating properties at the interface between the cap plate and terminal plate. The insulating layer may have different material characteristics than the bonding layer, with higher electrical resistance and appropriate surface properties for maintaining electrical isolation while still providing mechanical bonding functionality.
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 between the cap plate and terminal plate, enhancing the reliability and performance of button cells in wearable devices by preventing electrical contact and moisture ingress.
Implementation Method 1
a bonding layer between the cap plate and the terminal plate and insulating and bonding between the cap plate and the terminal plate
Implementation Method 2
an insulating structure adjacent to the bonding layer and located between the cap plate and an edge of the terminal plate
Data Source
AI summary
A button cell includes: an electrode assembly including a first electrode, a second electrode, and a separator between the first electrode and the second electrode; a case connected to the first electrode to accommodate the electrode assembly and including an opening exposing the electrode assembly; a cap plate coupled to the case to cover an outer area of the opening and including a through-hole exposing a central area of the opening; a terminal plate connected to the second electrode to be insulated from and bonded to the cap plate and covering the through-hole; a bonding layer between the cap plate and the terminal plate and insulating and bonding between the cap plate and the terminal plate; and an insulating structure adjacent to the bonding layer and located between the cap plate and an edge of the terminal plate.