Molded Retainer Current Collector for Battery Vibration Resistance
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Solution Overview
Problem
Existing secondary batteries face challenges in maintaining the stability and durability of the electrode assembly within the case, particularly against vibrations, and in ensuring electrical insulation and efficient production processes.
Innovation Solution
The design incorporates a retainer part molded to the current collector, which extends towards the case inner wall, providing electrical insulation and fixing the electrode assembly in place, while also allowing for automatic production and reducing weight and space, using materials like polyethylene or ABS resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate insulating member is used to prevent contact between the current collector and the case, then electrical insulation is achieved, but the number of parts increases and production complexity increases
Solution Approach 1:
The patent merges the insulating member with the current collector by molding the insulating member directly onto the current collector to form an integrated structure. This eliminates the need for separate assembly steps and reduces the number of discrete parts while maintaining electrical insulation functionality.
Solution Approach 2:
The insulating member is pre-formed on the current collector through molding before final assembly into the battery case. This preliminary action ensures insulation is already in place before the current collector is installed, simplifying the overall assembly process.
2Ease of manufacture
If the current collector structure is simplified without additional components, then ease of manufacture improves, but the electrode assembly may not be securely fixed against vibrations
Solution Approach 1:
The patent combines multiple functions into the current collector structure itself: electrical conduction, mechanical support, vibration damping, and insulation. By integrating these functions into a single molded component, the structure achieves vibration resistance without requiring separate fastening components.
Solution Approach 2:
The current collector is constructed as a composite structure combining conductive materials for electrical function with insulating materials for electrical isolation and vibration damping. This composite approach allows a single component to satisfy multiple requirements simultaneously.
3Ease of operation
If traditional assembly methods are used with separate components, then ease of assembly is maintained, but production speed and productivity are reduced
Solution Approach 1:
The insulating member and current collector are merged into a single molded component that can be produced in one manufacturing step. This eliminates multiple assembly operations (separate installation of insulating members, current collectors, and sealing elements) and enables direct installation into the battery case, significantly improving production speed.
4Reliability
If multiple separate components are used for current collection and insulation, then functional requirements are met, but the overall size and weight of the battery increase
Solution Approach 1:
The patent consolidates multiple components (current collector, insulating member, and sealing elements) into a single integrated molded structure. This reduction in component count directly decreases the total weight of the battery while maintaining all necessary functions through the multi-functional design of the integrated structure.
Data Source
AI summary
A secondary battery includes an electrode assembly having an electrode uncoated portion, a current collector having a pair of collecting parts coupled to the electrode uncoated portion, a case accommodating the electrode assembly, and a cap plate sealing an opening of the case. Each of the collecting parts includes a first surface facing an inner wall of the case. A retainer part extends toward the inner wall of the case from the first surface of each of the collecting parts. The retainer part is moldingly integrated with each of the collecting parts.