Feedthrough Insulator Cap for Battery Dendrite Short Prevention
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Solution Overview
Problem
Medical device batteries, particularly those with lithium chemistry, face issues with lithium ion dendrite growth leading to electrical shorting and reduced usable life due to the proximity of the ferrule and pin, which can cause premature failure.
Innovation Solution
A high-rate primary battery design featuring a feedthrough insulator cap that is reflowed onto the ferrule and pin, increasing the distance between them and reducing dendrite formation, thereby preventing short circuits and extending the battery's operational life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ferrule and pin are positioned close together in the battery, then the device complexity is reduced and manufacturing is simplified, but electrical shorting occurs due to lithium ion dendrite growth between them
Solution Approach 1:
An insulator cap is introduced as an intermediary component between the ferrule and pin to prevent direct contact and dendrite formation. The cap includes an insulating barrier that physically separates the conductive ferrule and pin, eliminating the electrical shorting pathway while maintaining structural integrity and simplifying the overall design.
2Reliability
If the distance between ferrule and pin is increased to prevent dendrite growth, then electrical shorting is reduced, but the battery structure becomes more complex and manufacturing more difficult
Solution Approach 1:
The insulator cap is integrated with the existing feedthrough structure, combining the insulation function with the mechanical support structure. The cap is positioned to engage with the ferrule and pin assembly as a unified component, allowing for streamlined manufacturing processes while maintaining the increased separation distance needed to prevent dendrite growth.
3Duration of action of stationary object
If a feedthrough insulator cap is added to insulate the ferrule and pin, then electrical shorting is prevented and battery life is extended, but the device complexity increases
Solution Approach 1:
The feedthrough structure is segmented into distinct functional components: the conductive ferrule, the insulating cap with barrier, and the pin. This segmentation allows each component to perform its specific function optimally while maintaining overall structural coherence. The insulator cap acts as a separate protective element that can be independently manufactured and assembled.
4Volume of stationary object
If the ferrule and pin are kept close together, then the battery size is reduced, but lithium ion dendrite growth causes electrical shorting and premature failure
Solution Approach 1:
The insulator cap utilizes a thin-walled structure that provides effective electrical insulation and physical separation between the ferrule and pin without occupying excessive space. The cap's streamlined design maintains compact battery dimensions while ensuring sufficient clearance to prevent dendrite growth and electrical shorting.
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 solution effectively reduces electrical shorting and increases the usable life of the battery by insulating the ferrule and pin, preventing dendrite growth and ensuring reliable power delivery for medical devices.
Implementation Method 1
a feedthrough insulator cap reflowed onto a portion of a feedthrough ferrule of the battery (the 'ferrule') and a portion of a unipolar electrical feedthrough pin of the battery (the 'pin')
Data Source
AI summary
A battery configured to support a relatively high rate of energy discharge relative to its capacity for energy intensive therapy delivery. The battery includes a feedthrough insulator cap disposed within the interior of the battery on at least a portion of a ferrule, at least a portion of an insulator, and at least a portion of a pin, which define a feedthrough extending through an enclosure of the battery; a first electrode disposed within the enclosure and electrically coupled to the pin; a second electrode disposed within the enclosure and separated a distance from the first electrode; and an electrolyte disposed between the first electrode and the second electrode. During operation of the battery, the feedthrough insulator cap reduces dendrite formation on at least a portion of the ferrule, the pin, or both.