Prismatic Battery Cap Assembly Deformable Plate Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Prismatic rechargeable batteries face challenges in safely managing excessive internal pressure, which can lead to explosions or combustion due to their unique terminal structure, making it difficult to cut off or discharge current effectively compared to cylindrical batteries.
Innovation Solution
A rechargeable battery design featuring a cap assembly with a deformable plate and an intermediate member that forms an electrical path between electrodes when deformed in response to increased pressure, using materials with higher melting points like aluminum or stainless steel, and a connecting bar to ensure safe short-circuiting and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a prismatic battery terminal structure is used, then the battery can be recharged and discharged, but it is difficult to cut off or discharge current when excessive heat or pressure occurs
Solution Approach 1:
The terminal structure incorporates a deformable plate that dynamically responds to internal pressure changes. When normal pressure exists, the plate maintains its original position allowing current flow. When excessive pressure occurs, the plate deforms to create an electrical path between first and second electrodes, automatically cutting off current without requiring complex mechanical switches or sensors.
Solution Approach 2:
The terminal structure uses the battery's own internal pressure as the actuating force to trigger the current cutoff mechanism. The deformable plate automatically deforms when pressure exceeds a threshold, creating a short circuit between electrodes that stops the chemical reactions and current flow, eliminating the need for external control systems.
2Object-affected harmful factors
If excessive heat or pressure is generated inside the battery, then the battery may explode or combust, but a safe structure to discharge current is difficult to implement
Solution Approach 1:
The invention converts the harmful effect of excessive internal pressure into a beneficial safety mechanism. The same pressure that could cause explosion or combustion is utilized to deform the plate and create an electrical path between electrodes, triggering a controlled short circuit that dissipates energy and prevents catastrophic failure.
Solution Approach 2:
The terminal structure is designed with a deformable plate that anticipates potential overpressure conditions. The plate is positioned and configured to deform at a specific pressure threshold, creating a pre-planned escape route for excess pressure and energy through controlled current cutoff, preventing the buildup of dangerous pressure levels.
3Reliability
If a deformable plate is used to create electrical path under pressure, then current can be discharged safely, but the plate material must have lower melting point than intermediate member
Solution Approach 1:
The terminal structure uses different materials with different melting points in specific locations. The deformable plate is made of a material with lower melting point than the intermediate member, allowing the plate to deform and create electrical contact first under excessive pressure. This localized material property difference ensures controlled short-circuiting while protecting the intermediate member and other battery components from direct exposure to extreme conditions.
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
The design effectively prevents battery explosions by creating a safe electrical connection and reducing heat buildup, enhancing the safety and longevity of prismatic rechargeable batteries by allowing for controlled pressure relief and preventing electrolyte ignition.
Implementation Method 1
The deformable plate may be configured to deform in response to an increase in pressure inside the case and cause the intermediate member to electrically contact the first tab to electrically couple the first electrode and the second electrode
Data Source
AI summary
A rechargeable battery includes an electrode assembly including a first electrode, a second electrode, and a separator between the first and second electrodes; a case housing the electrode assembly; and a cap assembly connected to the case. The cap assembly includes a first tab electrically connected to the first electrode, a second tab electrically connected to the second electrode, an deformable plate capable of electrically connecting the first tab and the second tab by being deformed due to a pressure increase, and an intermediate member formed between the first tab and the deformable plate.