Battery Cell Insulation Layout for Vibration-Induced Tab-to-Shell Shorts
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Solution Overview
Problem
Existing battery cells face safety concerns due to the risk of short circuits caused by contact between electrode tabs and the shell, particularly in vibration environments, where insulating treatments are lacking between the electrode tabs and the shell.
Innovation Solution
Incorporating an insulating part that extends from an insulating main body and is partially located between the outer and inner circumferential surfaces of the battery core and shell, effectively isolating the electrode tabs from the shell to prevent short circuits, and optionally using a second insulating component to further stabilize and separate the battery core from the shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrode tabs are placed near the shell to improve space utilization, then energy density is improved, but the risk of short circuit increases due to contact between electrode tabs and shell
Solution Approach 1:
An insulating component is introduced as an intermediary element between the electrode tabs and the shell. The insulating component includes an insulating main body positioned between the battery core and end cover, and an insulating part that extends from the insulating main body to contact or approach the electrode tabs, preventing direct contact between the electrode tabs and the shell while allowing close spacing for high energy density.
2Reliability
If insulating treatment is added between electrode tabs and shell to prevent short circuit, then safety is improved, but device complexity increases
Solution Approach 1:
The insulating component merges multiple functions into a single element: the insulating main body provides isolation between the battery core and end cover, while the insulating part extending from it provides isolation between the electrode tabs and shell. This integrated design prevents short circuits without requiring multiple separate insulating elements, thereby limiting the increase in structural complexity.
Solution Approach 2:
The insulating component serves multiple purposes: it acts as an insulator between the battery core and end cover, provides insulation between electrode tabs and shell, and can also serve as a positioning or support structure. This multi-functionality reduces the need for additional components, offsetting the complexity added by the insulating treatment.
3Reliability
If insulating component is added to isolate electrode tabs from shell, then short circuit risk is reduced, but manufacturing complexity increases
Solution Approach 1:
The insulating component is pre-formed with the insulating main body and insulating part integrated together before assembly. This preliminary preparation allows the insulating component to be installed as a single piece during battery assembly, avoiding the need for complex on-site insulation treatments and simplifying the manufacturing process while ensuring reliable short circuit prevention.
Data Source
AI summary
A battery cell, a battery, an electrical device, and a method and device for manufacturing the battery cell. In some embodiments, the battery cell comprises a battery core, a shell, an end cover, and a first insulating component. The battery core comprises a main body part and electrode tabs protruding from the main body part. The shell has a first opening and is configured to accommodate the battery core. The end cover is configured to cover the first opening. The first insulating component comprises an insulating main body and an insulating part, wherein the insulating main body is located on a side, facing the electrode tabs, of the end cover, and the insulating main body is configured to isolate the battery core from the end cover.