Isolated Sleeve Cell Housing With Integrated End Caps
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Solution Overview
Problem
Existing cylindrical energy storage devices face challenges in manufacturing complexity and material selection limitations due to direct electrical connections between the cell sleeve and end caps or terminals, leading to increased costs and potential chemical interactions.
Innovation Solution
The cell sleeve is electrically isolated from the end caps and terminals, allowing 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 material constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cell sleeve is directly connected to end caps or terminals, then electrical connection is achieved, but manufacturing complexity and material selection limitations increase
Solution Approach 1:
The device is divided into electrically isolated components: the cell sleeve is separated from the end caps and terminals through electrical isolation mechanisms (insulating layers or non-conductive materials). This segmentation allows independent optimization of each component's material and manufacturing process, reducing overall manufacturing complexity while maintaining electrical functionality.
Solution Approach 2:
An intermediary insulating structure or non-conductive material is introduced between the cell sleeve and the end caps/terminals. This intermediary element provides electrical isolation while still allowing mechanical coupling and structural integrity, simplifying the overall connection architecture by decoupling electrical and mechanical functions.
2Adaptability or versatility
If the cell sleeve is directly connected to end caps or terminals, then structural integrity is maintained, but material selection is limited due to chemical interaction risks
Solution Approach 1:
An insulating intermediary layer or non-conductive material is placed between the cell sleeve and electroactive components (end caps, terminals). This intermediary prevents direct chemical contact and potential harmful reactions while allowing electrical isolation and maintaining structural integrity through mechanical coupling.
Solution Approach 2:
The design creates an electrically inert environment around the cell sleeve by using non-conductive materials or insulating coatings. This inert electrical environment prevents unwanted electrochemical reactions at the sleeve interface, enabling the use of a broader range of sleeve materials that would otherwise be incompatible with direct electrical contact.
3Reliability
If one end cap is electrically isolated from the sleeve using gaskets, then electrical isolation is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The electrical isolation function is merged with the structural sealing function by integrating the insulating layer directly into the end cap or sleeve design. This consolidation eliminates the need for separate gasket components while maintaining both electrical isolation and mechanical sealing, thereby reducing device complexity and manufacturing steps.
Solution Approach 2:
The insulating structure is designed to perform multiple functions simultaneously: providing electrical isolation, maintaining mechanical sealing, and ensuring structural integrity. This multi-functionality reduces the number of separate components needed (such as dedicated gaskets), simplifying the overall device architecture and manufacturing process.
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.