Folded Insulation Sheet Assembly for Stable Bare Cell Wrapping
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Solution Overview
Problem
Existing energy storage devices face issues with low wrapping efficiency and stability due to separate insulating sheets that require multiple processes and seam warping, leading to potential safety risks from bonding failures.
Innovation Solution
A protective film assembly with an integrated insulation sheet featuring fold structures that divide into multiple regions, allowing for seamless wrapping and increased bonding areas, ensuring structural stability and improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulating sheets are used for wrapping the bare cell, then the insulation protection is achieved, but the wrapping efficiency is low and the bonding area is small
Solution Approach 1:
The patent combines multiple separate insulating sheets (bottom insulating sheet, main wrapping sheet, and auxiliary wrapping sheet) into a single integrated insulating sheet with one body. This integrated sheet includes a bottom surface covering region, a main surface covering region, and first and second side surface covering regions that are all connected as one piece, eliminating the need for multiple separate components and improving wrapping efficiency while maintaining insulation protection.
Solution Approach 2:
The integrated insulating sheet is divided into multiple functional regions (bottom surface covering region, main surface covering region, first side surface covering region, second side surface covering region) through fold structures. These regions are segmented to cover different surfaces of the bare cell while remaining part of a single integrated structure, allowing efficient wrapping without requiring multiple separate sheets.
2Reliability
If multiple separate wrapping sheets are used, then the insulation coverage is complete, but the seams between sheets are prone to warping and bonding failure
Solution Approach 1:
By merging multiple separate wrapping sheets into a single integrated insulating sheet, the patent eliminates the seams and joints that exist between separate sheets. The integrated structure ensures uniform wrapping without warping at connection points, as there are no separate components to bond together, thereby improving wrapping stability while maintaining complete insulation coverage.
3Reliability
If separate insulating sheets are used, then the insulation function is achieved, but the bonding area is small leading to bonding failure
Solution Approach 1:
The integration of multiple insulating sheet functions into one single insulating sheet creates continuous bonding surfaces without interruption. The first and second side surface covering regions overlap after bending, forming extensive bonding areas that are free from the limitations of separate sheet connections, thereby ensuring reliable bonding while maintaining insulation function.
4Reliability
If multiple separate insulating sheets and zoned wrapping processes are used, then the insulation protection is achieved, but the manufacturing complexity is high
Solution Approach 1:
The patent simplifies manufacturing by combining multiple insulating sheets and zoned wrapping processes into a single integrated insulating sheet that can be wrapped in one operation. The integrated sheet includes all necessary regions (bottom, main, and side surface covering regions) connected together, eliminating the need for separate component collection, sorting, and zoned wrapping processes, thereby reducing manufacturing complexity while maintaining insulation protection.
Data Source
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AI summary
The present disclosure discloses a protective film assembly, applied to an electrode assembly (300) of an energy storage device (1000), and including an insulation sheet (100) for wrapping the electrode assembly (300) , and arranged between a housing of the energy storage device (1000) and the electrode assembly (300). The insulation sheet (100) is integrated, and is provided with a plurality of fold structures (150) , which divide the insulation sheet (100) into a bottom surface covering region (140) clinging to a bottom of the electrode assembly (300), a main surface (110) covering region clinging to a main surface of the electrode assembly (300), and a first side surface (120) covering region and a second side surface (130) covering region clinging to side surfaces of the electrode assembly (300). The first side surface (120) covering region includes a first covering sub-region (121) and a second covering sub-region (122) which can overlap each other; the second side surface (130) covering region includes a third covering sub-region (131) and a fourth covering sub-region (132) which can overlap each other; a maximum sizes of the first covering sub-region (121) and the second covering sub-region (122) in a thickness direction and height direction of the electrode assembly are equal, so that the first covering sub-region (121) and the second covering sub-region (122) have a high matching degree and a large bonding area. The present disclosure further discloses an energy storage device (1000).