Integrated Insulation Member for Secondary Battery Safety
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Solution Overview
Problem
Existing secondary batteries face challenges in effectively insulating the electrode assembly from the case and managing gas generated during charging/discharging, which can lead to electrical shorts and safety issues.
Innovation Solution
A secondary battery design incorporating a one-piece, integrally formed insulation member with distinct regions that electrically insulate the electrode assembly from the case, including a terminal protrusion, vent hole, and reinforcing structures, formed from materials like phenol resin or polyphenylene sulfide, to direct gases towards a safety vent and prevent electrical shorts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulating components are used to isolate the electrode assembly from the case, then insulation effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple separate insulating components (insulating member, gasket, and terminal insulator) into a single integrated insulating structure. This insulating structure includes a body portion positioned between the electrode assembly and case, a flange portion extending from the body, and a terminal insulator integrated into the flange, thereby reducing component count while maintaining insulation effectiveness
Solution Approach 2:
The integrated insulating structure performs multiple functions simultaneously: the body portion provides insulation between the electrode assembly and case, the flange portion seals the gap between the cap plate and case, and the integrated terminal insulator isolates the terminal from the cap plate, eliminating the need for separate specialized components
2Reliability
If multiple separate insulating components are used, then insulation coverage is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent merges multiple insulating functions into a single molded component that can be manufactured as one piece. The integrated insulating structure includes the body portion, flange portion, and terminal insulator all formed in a single manufacturing process, eliminating the need for separate assembly steps and reducing manufacturing complexity
3Device complexity
If a one-piece insulating structure is used, then device complexity is reduced, but insulation effectiveness may worsen
Solution Approach 1:
The integrated insulating structure is designed with distinct functional segments: the body portion for electrode-case insulation, the flange portion for sealing, and the integrated terminal insulator for terminal isolation. Each segment is optimized for its specific function while being manufactured as a single integrated component, ensuring insulation effectiveness is not compromised
4Manufacturing precision
If separate insulating components are used, then insulation precision is improved, but productivity deteriorates
Solution Approach 1:
The patent combines multiple insulating components into a single integrated structure that is installed as one piece. This eliminates the need for multiple separate installation steps, positioning operations, and adjustments, thereby improving assembly speed and productivity while maintaining precise insulation positioning through the integrated design
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A secondary battery (100) including an electrode assembly (110), the electrode assembly (110) including an uncoated region at ends thereof; a case (150) accommodating the electrode assembly (110); a cap plate (160) coupled with the case (150); and an insulation member (140) in the case (150), the insulation member (140) including a first region (141) between the electrode assembly (110) and the cap plate (160), and a second region (142) between the uncoated region of the electrode assembly (110) and an inner surface of the case (150).