Folded Box Insulating Sheet for Battery Electrode Assembly
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Solution Overview
Problem
The existing configuration of power storage devices, such as electric vehicle batteries, often results in exposure of the electrode assembly due to gaps between the electrode assembly and the case, compromising insulation.
Innovation Solution
A power storage device design featuring an electrode assembly with a layered structure and an insulating sheet shaped like a folded box, where primary-face covering portions are continuous with non-primary-face covering portions, ensuring no gaps and improved insulation by overlapping these portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating sheet is shaped like a spread polygon and assembled with adjacent sides butted, then the electrode assembly can be covered, but gaps occur between the butted sides causing exposure of the electrode assembly and poor insulation
Solution Approach 1:
The insulating sheet is divided into multiple covering portions (first covering portion, second covering portion, third covering portion, fourth covering portion) that wrap around the electrode assembly in sequence, with each portion overlapping the previous one to eliminate gaps while maintaining coverage
Solution Approach 2:
The insulating sheet portions are arranged in a nested wrapping configuration where each subsequent covering portion overlaps and covers the edges of the previous portion, creating a layered protective structure that eliminates exposure gaps
2Reliability
If a complicated shaped insulating sheet is used to prevent gaps, then insulation is improved, but manufacturing complexity and costs increase
Solution Approach 1:
Instead of cutting the insulating sheet into a complicated pre-formed shape, the invention uses a simple rectangular sheet and creates the protective structure through folding and wrapping, inverting the approach from complex shape to simple shape with complex arrangement
Solution Approach 2:
The insulating sheet is used as a flexible thin film that can be wrapped and folded around the electrode assembly, allowing a simple rectangular sheet to conform to the assembly shape and provide complete coverage without requiring complex pre-formed geometry
Data Source
AI summary
A power storage device includes an electrode assembly, a case that houses the electrode assembly, and an insulating sheet, which insulates the electrode assembly and the case from each other. The electrode assembly has a layered structure in which positive electrodes and negative electrodes are stacked. The electrode assembly has a first end face, which is orthogonal to the stacking direction, two primary faces, which are located on both sides in the stacking direction, and a tab, which extends on the first end face in the direction orthogonal to the stacking direction. The insulating sheet has a folded box shape, and further has two primary face covering portions, which respectively cover the primary faces of the electrode assembly, and non-primary-face covering portions, which cover the first end face of the electrode assembly and faces other than the primary faces thereof and are continuous with the primary face covering portions. The non-primary face covering portions overlap at least partially with each other.