Isolated Cell Sleeve and End Cap Assembly for Easier Battery Manufacturing
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Solution Overview
Problem
Existing cylindrical energy storage devices face challenges in manufacturing complexity and material limitations due to direct electrical connections between the cell sleeve and end caps or terminals, leading to increased costs and reduced material selection options, and complex designs are required for electrical isolation, which complicates the manufacturing process.
Innovation Solution
The cell sleeve is electrically isolated from the end caps and terminals, allowing for the use of non-conductive materials like polymers and rubbers, and a multi-piece assembly process that simplifies manufacturing by forming the sleeve to act as a gasket and seal, reducing assembly steps and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cell sleeve is directly connected to end caps or terminals, then electrical connection is achieved, but material selection is limited and manufacturing complexity increases
Solution Approach 1:
The cell assembly is segmented into distinct electrical components: the sleeve, end caps, and terminals are separated by insulating elements. This segmentation allows each component to be made from optimal materials independently, with the sleeve providing mechanical containment and the end caps/terminals providing electrical connection, resolved by introducing insulating barriers between them.
Solution Approach 2:
An insulating element acts as an intermediary between the conductive sleeve and the conductive end caps/terminals. This intermediary prevents direct electrical connection while maintaining mechanical structural integrity, allowing the sleeve to be made from materials optimized for mechanical properties rather than electrical conductivity.
2Strength
If the cell sleeve is directly connected to end caps or terminals, then structural integrity is maintained, but manufacturing cost increases
Solution Approach 1:
The assembly is divided into modular segments (sleeve, insulating element, end caps, terminals) that can be manufactured separately using optimized processes for each material type, then assembled together. This segmentation enables parallel manufacturing and reduces the need for expensive multi-material forming operations.
Solution Approach 2:
The insulating element serves as a simple intermediary component that can be easily inserted or attached between the sleeve and end caps, providing both electrical isolation and mechanical coupling without requiring complex integrated structures or expensive specialized manufacturing processes.
3Adaptability or versatility
If complex designs are used for electrical isolation, then material selection expands, but device complexity increases
Solution Approach 1:
The insulating element performs multiple functions simultaneously: it provides electrical isolation between conductive components, maintains mechanical structural integrity of the assembly, and enables the use of diverse materials for the sleeve and end caps. This multi-functionality simplifies the overall design by consolidating isolation and structural roles into a single component.
Solution Approach 2:
The insulating element is made from a homogeneous non-conductive material that provides consistent electrical isolation properties throughout, simplifying design calculations and material selection compared to complex composite structures or multi-layer designs that would be needed to achieve both isolation and structural functions separately.
Data Source
AI summary
The present invention relates to energy storage devices and more particularly to their design and manufacturing method. The energy storage device comprises an electrically isolated cylindrical sleeve housing open at both ends and closed with two separate end caps integrated with the current terminals with an improved design. The upper and lower end caps are integrated with the anode and cathode terminals, and the cylindrical sleeve housing is electrically isolated from both upper and lower end caps integrated with the current collector terminals. Unlike previously known solutions the cylindrical sleeve housing is electrically isolated both from the upper and lower current terminals which are integrated directly into the end caps wherein this is to avoid undesirable side reactions and the disruption of energy storage mechanism. Additionally, the upper and lower end caps are directly integrated with the current terminals and offer an improved design.