Battery Cap Plate Insulation With Uneven Surface Interlocking

Solution Overview

Problem

Secondary batteries are prone to becoming inoperable due to short circuits when positive and negative polarity parts come into contact, necessitating effective insulation methods to prevent such occurrences.

Innovation Solution

The integration of an insulating member with the cap plate and terminal through an insert injection process, featuring nano-anchors and larger-scale unevennesses to enhance adhesion and prevent crack propagation, thereby ensuring effective insulation and improved battery functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulating member is integrally formed with the cap plate and terminal through an insert injection process, then the insulation effectiveness is improved, but the adhesion between components may be insufficient leading to potential short circuits

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidadhesion between cap plate, terminal, and insulating member

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies preliminary action by forming unevennesses (protrusions or recesses) on the contact surfaces of the cap plate and terminal before the insert injection process. This pre-prepared surface structure enables the injection-molded insulating member to mechanically interlock with these components, ensuring strong adhesion from the outset and preventing subsequent separation that could lead to short circuits.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs composite materials by integrating the insulating member (made of insulating material) with the cap plate and terminal through the insert injection process. This creates a composite structure where the insulating member and metal components are firmly bonded, providing both electrical insulation and mechanical strength to prevent short circuits while maintaining component integrity.

Inventive Principle:

Principle #40Composite materials

2Device complexity

If the insulating member is integrally formed with the cap plate and terminal, then the structural complexity is reduced, but the adhesion strength may be insufficient

Engineering Contradiction:

Improvestructural complexityVSAvoidadhesion strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent applies preliminary action by forming unevennesses (protrusions or recesses) on the contact surfaces of the cap plate and terminal before the insert injection process. This pre-prepared surface structure enables the injection-molded insulating member to mechanically interlock with these components, ensuring strong adhesion from the outset and preventing subsequent separation that could lead to short circuits.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If the insulating member is formed without surface unevennesses, then the manufacturing process is simpler, but crack propagation may occur reducing reliability

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidresistance to crack propagation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by forming unevennesses (protrusions or recesses) on the contact surfaces of the cap plate and terminal before the insert injection process. This pre-prepared surface structure enables the injection-molded insulating member to mechanically interlock with these components, ensuring strong adhesion from the outset and preventing subsequent separation that could lead to short circuits.

Inventive Principle:

Principle #10Preliminary action

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 solution significantly enhances the adhesion between the cap plate, terminal, and insulating member, reducing the risk of short circuits and improving the overall reliability and performance of the secondary battery.

Implementation Method 1

At least one of a surface of the cap plate contacting the insulating member and a surface of the terminal contacting the insulating member has an unevenness formed thereon

Methodology Applied

Scientific EffectMechanical interlocking:

Implementation Method 2

At least one of a surface of the cap plate contacting the insulating member and a surface of the terminal contacting the insulating member has an unevenness formed thereon

Methodology Applied

Scientific EffectSurface area increase:

Implementation Method 3

The insulating member may be integrally formed with the cap plate and the terminal through an insert injection process

Methodology Applied

Scientific EffectInsert injection molding:

Data Source

PatentUS20240332685A1Secondary battery

Publication Date: 2024.10.03 SAMSUNG SDI CO LTD

AI summary

A secondary battery includes: an electrode assembly including a first electrode plate, a second electrode plate, and a separator; a case accommodating the electrode assembly; a cap plate coupled to the case and having a terminal hole passing therethrough; a terminal over the terminal hole in the cap plate; a current collecting member electrically connecting the electrode plate and the terminal; and an insulating member insulating the cap plate and the terminal from each other and insulating the cap plate and the current collecting member from each other. At least one of a surface of the cap plate contacting the insulating member and a surface of the terminal contacting the insulating member has an unevenness formed thereon.