Electrochemical Cell Cap With Integrated Diaphragm
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Solution Overview
Problem
Existing cell caps are often complex and require multiple components, leading to costly and time-consuming manufacturing processes, and may suffer from leakage issues due to multiple potential leak paths.
Innovation Solution
A simplified cell cap design featuring a substantially flat member with a separation portion and a diaphragm that covers the separation portion on the inside, where the diaphragm inverts and ruptures at specific pressures to interrupt current flow and prevent electrolyte leakage, utilizing a material weakening and weld joint for structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing cell caps use multiple components and complex structures, then current interruption and venting functionality can be achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent combines the current interruption device (CID) and diaphragm into a single integrated cap structure. The CID is formed as a protrusion on the inner surface of the cap, while the diaphragm is positioned within the same cap body, eliminating the need for separate CID housings and reducing assembly steps. This merging maintains safety functionality while reducing component count and manufacturing complexity.
2Strength
If existing cell caps use multiple components and assembly steps, then structural integrity can be achieved, but manufacturing time and costs increase
Solution Approach 1:
The cap is designed with distinct functional zones: an outer cap structure for mechanical strength and sealing, an integrated CID protrusion for current interruption, and an inner diaphragm for venting control. This segmentation allows each zone to be optimized independently while being manufactured as a unified structure, maintaining structural integrity through clear functional boundaries without requiring complex multi-step assembly.
3Reliability
If existing cell caps have multiple potential leak paths, then current interruption functionality is maintained, but leakage issues increase
Solution Approach 1:
The diaphragm serves as an intermediary element positioned between the cell interior and exterior environment. It selectively controls fluid passage based on pressure conditions: remaining intact during normal operation and CID activation to prevent leakage, while allowing venting when pressure exceeds the diaphragm's rupture pressure. This intermediary structure eliminates uncontrolled leak paths while maintaining necessary safety functions.
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 reduces manufacturing complexity and costs, minimizes leakage, allows for a more compact cell cap, and enhances current interruption and venting functionality, enabling safer and more efficient operation of electrochemical cells.
Implementation Method 1
the diaphragm inverts and ruptures at specific pressures to interrupt current flow and prevent electrolyte leakage
Implementation Method 2
utilizing a material weakening and weld joint for structural integrity
Data Source
AI summary
An electrochemical cell includes: a cell can; electrolyte and an active-material roll in the cell can; and a cap that closes at least one opening of the cell can, the cap comprising: a substantially flat member that covers the opening, the substantially flat member having a separation portion defined therein; and a diaphragm that covers the separation portion on an inside of the substantially flat member.