Laminating Insulating Layer Reduces Battery Height

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Solution Overview

Problem

Conventional rechargeable batteries face challenges in efficiently managing internal pressure and gas discharge, leading to increased manufacturing costs and battery height due to the use of conventional insulating members.

Innovation Solution

Incorporating a laminating insulating layer made of polypropylene-based resin between the vent plate and the middle plate, with an optional thermally fusing insulating layer of polybutylene-based resin, to enhance insulation and reduce the overall height and volume of the battery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional insulating members are used between the vent plate and middle plate, then insulation is provided, but the battery height and volume increase

Engineering Contradiction:

ImproveinsulationVSAvoidbattery height

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent applies this principle by using a thin film insulating layer (comprising a lower insulating layer and an upper insulating layer) instead of conventional bulky insulating members. The film structure provides the necessary insulation between the vent plate and middle plate while maintaining a compact thickness, thus reducing the overall battery height without compromising insulation reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If conventional insulating members are used between the vent plate and middle plate, then insulation is provided, but manufacturing cost increases

Engineering Contradiction:

ImproveinsulationVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the insulating function with the sealing function by integrating the insulating layers into the cap plate structure. The lower insulating layer and upper insulating layer are combined with sealing layers to form an integrated cap plate assembly, eliminating the need for separate insulating members and reducing manufacturing complexity and cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite material structures where the insulating layers are made from resin materials that provide both insulation and sealing properties. The combination of different resin materials with complementary properties creates a multi-functional composite structure that reduces the need for additional components and lowers overall manufacturing cost.

Inventive Principle:

Principle #40Composite materials

3Volume of stationary object

If the insulating layer is made thinner to reduce battery height, then volume is reduced, but insulation stability may be compromised

Engineering Contradiction:

Improvebattery volumeVSAvoidinsulation stability

Core Design Contradiction:

Volume of stationary objectVSStability of the object's composition

Solution Approach 1:

The patent employs composite material structures with multiple insulating layers (lower insulating layer and upper insulating layer) made from different resin materials. This multi-layer composite approach maintains effective insulation stability even at reduced thickness by distributing the insulation function across multiple layers with complementary electrical and mechanical properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies asymmetry by designing the lower insulating layer and upper insulating layer with different thicknesses and material compositions optimized for their specific positions. The lower insulating layer (first thickness) and upper insulating layer (second thickness) are asymmetrically designed to provide optimal insulation stability while minimizing overall volume, with each layer tailored to its specific functional requirements.

Inventive Principle:

Principle #4Asymmetry

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

This configuration provides stable insulation while reducing the total height and volume of the rechargeable battery, improving its structural integrity and manufacturing efficiency compared to conventional designs.

Implementation Method 1

a laminating insulating layer disposed between the vent plate and the middle plate and adhered to the vent plate or the middle plate by laminating

Methodology Applied

Scientific EffectLaminating: Lamination

Implementation Method 2

the thermally fusing insulating layer adhered to the laminating insulating layer by thermal fusing

Methodology Applied

Scientific EffectThermal fusing:

Data Source

PatentUS9601736B2Rechargeable battery having insulation layer

Publication Date: 2017.03.21 SAMSUNG SDI CO LTD

AI summary

A rechargeable battery includes an electrode assembly including a positive electrode and a negative electrode, a case receiving the electrode assembly, a cap plate coupled to the case, a vent plate under the cap plate, the vent plate including a notch, a middle plate under the vent plate, and a laminating insulating layer between the vent plate and the middle plate, the laminating insulating layer being laminated to the vent plate or the middle plate.