Folded Headspace Insulator for Stable Battery Cell Isolation

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Solution Overview

Problem

Implantable medical device batteries face issues with insulator shifting, exposing internal components to external forces and electrical shorts, which affect battery longevity and patient comfort.

Innovation Solution

A battery design featuring a headspace insulator with an upper and lower portion joined by a neck, inserted between the battery cell and top cover, providing mechanical stability, electrical insulation, and allowing electrolyte passage, manufactured from materials like ETFE and polypropylene to prevent shorts and enhance thermal insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional insulator is used in the battery, then electrical insulation is provided, but the insulator can shift position and leave internal components vulnerable to outside forces or electrical shorts

Engineering Contradiction:

Improveelectrical insulation reliabilityVSAvoidinsulator position stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The insulator is divided into multiple segments: a head portion, a body portion, and a tail portion. Each segment serves a specific function - the head portion provides electrical insulation, the body portion maintains structural integrity, and the tail portion anchors the insulator to prevent shifting. This segmentation allows the insulator to maintain position stability while preserving electrical insulation reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulator is nested within the battery assembly, with the head portion positioned in the headspace, the body portion extending downward, and the tail portion anchored to the battery can. This nested configuration ensures the insulator remains securely positioned while maintaining its electrical insulation function throughout the battery's operational life.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Stability of the object's composition

If the insulator is made more rigid to prevent shifting, then position stability improves, but the battery cell may be more vulnerable to external forces

Engineering Contradiction:

Improveinsulator position stabilityVSAvoidbattery cell protection

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

Different portions of the insulator have different mechanical properties optimized for their specific functions. The head portion is more rigid to maintain electrical insulation, while the body and tail portions have graduated rigidity that allows them to absorb and distribute external forces, protecting the battery cell without compromising position stability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The insulator is constructed from composite materials or a gradient material structure that combines regions of high rigidity (for position stability) with regions of controlled flexibility (for shock absorption). This composite construction allows the insulator to simultaneously prevent shifting and protect the battery cell from external forces.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If the insulator fully encloses the battery cell for maximum protection, then mechanical stability improves, but electrolyte passage is blocked

Engineering Contradiction:

Improvebattery cell stabilityVSAvoidelectrolyte filling efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The insulator incorporates porous regions or controlled openings that allow electrolyte to pass through during battery assembly and filling operations. These porous structures maintain the insulator's mechanical stability and position-finding function while enabling efficient electrolyte distribution to the battery cell.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The insulator is designed with pre-formed channels and openings that guide electrolyte flow during the battery assembly process. This preliminary structural configuration ensures efficient electrolyte filling before the battery is sealed, maintaining both mechanical stability and productivity.

Inventive Principle:

Principle #10Preliminary action

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 headspace insulator effectively stabilizes the battery cell, prevents electrical shorts, and ensures prolonged battery performance by maintaining mechanical and electrical integrity, enhancing the longevity and reliability of implantable medical devices.

Implementation Method 1

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

manufactured from materials like ETFE and polypropylene to prevent shorts and enhance thermal insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12102832B2Folded headspace insulator

Publication Date: 2024.10.01 MEDTRONIC INC

AI summary

A battery comprising a tubular battery housing having a first end and a second end. The first end and the second end can have a substantially same inner diameter and a substantially same outer diameter. The battery further comprises a battery cell within the tubular battery housing. The battery further comprises a top battery cover coupled to the first end and a bottom battery cover coupled to the second end to form a substantially sealed enclosure around the battery cell. Method for manufacturing the battery are also described.