Cylindrical Battery Cap Insulation to Prevent Sealing Short Circuits
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Solution Overview
Problem
Existing manufacturing processes for cylindrical batteries face a high risk of short-circuiting during the sealing process.
Innovation Solution
A cylindrical battery design featuring a shaft core with conductive and insulating parts, an insulating member with protrusions, and a sealing resin to prevent short-circuiting, along with a battery module comprising multiple such batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional sealing process is used during cylindrical battery manufacturing, then the manufacturing process is simple, but the risk of short-circuiting increases
Solution Approach 1:
An insulating member is introduced as an intermediary component between the cap and the wound electrode assembly. This insulating member features a protrusion that extends into the interior of the exterior member, creating a physical barrier that prevents direct contact between conductive parts. The intermediary structure effectively blocks potential short-circuit paths without requiring fundamental changes to the sealing process itself.
Solution Approach 2:
The insulating member utilizes the radial dimension by extending a protrusion from the cap region inward toward the wound electrode assembly. This three-dimensional configuration creates multiple layers of insulation in the radial direction, preventing short-circuits that might occur in conventional two-dimensional sealing arrangements. The protrusion effectively adds a spatial dimension to the insulation strategy.
2Reliability
If an insulating member with protrusion is added to prevent short-circuiting, then short-circuiting risk is reduced, but manufacturing complexity increases
Solution Approach 1:
The insulating member is integrated with the cap assembly, combining two functional elements into a unified component. The protrusion of the insulating member is positioned to work in conjunction with the sealing structure, allowing the sealing and insulation functions to be achieved simultaneously during the sealing process. This merging reduces the number of separate assembly steps required.
Solution Approach 2:
The insulating member with its protrusion is pre-positioned on the cap before the sealing operation. This preliminary arrangement ensures that the insulation barrier is already in place before the sealing process begins, preventing short-circuiting during manufacturing without requiring additional steps after sealing. The protrusion is strategically positioned in advance to intercept potential short-circuit paths.
Data Source
AI summary
Provided is a cylindrical battery including: a shaft core; a set of wound electrodes including an electrode stack wound on the shaft core; an exterior member surrounding the set of wound electrodes; a cap disposed at one axial end of the shaft core and electrically connected to one of the positive and negative electrodes; and an insulating member disposed between the exterior member and the cap, the cap having an outer diameter that is larger than the inner diameter of the exterior member and smaller than the outer diameter of the exterior member, the insulating member having an outer diameter larger than the outer diameter of the cap, the insulating member having a protrusion that is located more inside in the radial direction of the set of wound electrodes than the inner surface of the exterior member and protrudes toward the set of wound electrodes.