Dual-Case Rechargeable Battery with Insulating Layer and Asymmetric Coupling
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Solution Overview
Problem
Rechargeable batteries face challenges in safety and total height dispersion, particularly in ultra-small designs for wearable devices, where structural stability and impact resistance are critical.
Innovation Solution
A rechargeable battery design featuring a first and second case with insulating material between them, along with protruded and accommodating parts for secure coupling, preventing separation and rotation under impact and ensuring electrical insulation, thus maintaining electrode tab connectivity and reducing height variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery size is reduced for wearable devices, then the portability and wearability are improved, but the electrical capacity and energy density become insufficient
Solution Approach 1:
The battery case is divided into a first case and a second case that are coupled together. The first case has accommodating parts that receive protruded parts from the second case, creating a segmented structure. This segmentation allows for optimized internal space arrangement, enabling the electrode assembly to be efficiently packed within the compact case while maintaining required electrical capacity.
2Volume of moving object
If the battery components are tightly coupled to reduce size, then the compactness is improved, but the structural stability and impact resistance deteriorate
Solution Approach 1:
An insulating material is placed between the first case and the second case before they are coupled together. This insulating material acts as a cushioning layer that absorbs impact forces and prevents direct metal-to-metal contact. The cushioning effect maintains structural stability and prevents case separation or electrode tab breakage during drops or impacts, while still allowing the cases to be tightly coupled for compactness.
3Ease of manufacture
If the cases are directly coupled without insulation, then the manufacturing simplicity is improved, but the electrical safety and insulation performance worsen
Solution Approach 1:
An insulating material is introduced as an intermediary between the first case and the second case. This insulating material prevents direct electrical contact between the cases, ensuring electrical safety and preventing short circuits between positive and negative terminals. The insulating material can be a simple sheet or coating that is easily applied during manufacturing, maintaining ease of manufacture while significantly improving electrical reliability.
4Stability of the object's composition
If multiple coupling points are added to prevent rotation and separation, then the structural stability is improved, but the device complexity increases
Solution Approach 1:
The coupling structure uses asymmetric protruded parts and accommodating parts with specific geometric shapes. The protruded parts have shapes such as quarter ellipses, semi-ellipses, triangles, or quadrangles, while the accommodating parts have corresponding concave shapes. This asymmetric geometry provides inherent anti-rotation functionality, preventing the second case from rotating relative to the first case during impacts. The asymmetric design achieves structural stability with minimal coupling points, avoiding excessive complexity.
Data Source
AI summary
A rechargeable battery according to an embodiment of the present invention includes: a first case receiving an electrode assembly and having a first opening; a second case having a second opening smaller than the first opening and coupled to the inner surface of the first case with the outer surface while covering the electrode assembly; an insulating material interposed between the first case and the second case to form an electrically insulating state; a plurality of protruded parts protruded onto the outer surface of the second case; and a plurality of accommodating parts formed in the first case and coupled to the protruded part, wherein the first case and the second case are concluded to form a closed state when the protruded part is coupled to the accommodating part.