Prismatic Battery Fixing Projections Insulating Sheet
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Solution Overview
Problem
Prismatic batteries face issues with insertability and short-circuiting due to unevenness and vibration, which affect their reliability and manufacturing efficiency, especially in electric vehicles and hybrid electric vehicles where large currents are involved.
Innovation Solution
A prismatic battery design with a flat electrode assembly where the positive and negative electrode collectors have a fixing portion that projects less than the thickness of the insulating sheet, ensuring secure positioning and preventing short-circuits, even under vibration, by using a folded insulating resin sheet with a U-shaped cross-section to cover the electrode assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a projection for positioning is provided on the positive electrode collector or negative electrode collector to prevent short-circuiting, then reliability is improved, but insertability deteriorates due to increased friction and difficulty in insertion
Solution Approach 1:
The invention changes the geometric parameters of the projection, specifically limiting its height to be less than the thickness of the insulating sheet. This parameter optimization allows the projection to maintain positioning function while reducing insertion resistance and friction, thereby resolving the contradiction between reliability and insertability
2Reliability
If the projection height is increased to ensure positioning stability, then reliability is improved, but manufacturing precision deteriorates due to center line deviation causing short-circuits
Solution Approach 1:
The invention optimizes the projection height parameter to be less than the insulating sheet thickness, creating a safety margin that tolerates center line deviations during manufacturing. This parameter change ensures that even with slight misalignments, the projection remains embedded in the insulating sheet without causing short-circuits, thus resolving the contradiction between positioning stability and manufacturing precision
3Reliability
If a protective material or insulating material is formed on the outer circumference of the flat electrode assembly, then reliability is improved by preventing damage and short-circuits, but device complexity increases
Solution Approach 1:
The invention merges the protective/insulating function with the positioning function by integrating the insulating sheet into the existing projection structure. The insulating sheet serves dual purposes: protecting the electrode assembly from damage and short-circuits, and providing a medium for the projection to embed into for positioning. This merging reduces overall device complexity while maintaining reliability
Data Source
AI summary
A prismatic battery is provided with a fixing portion composed of projections 29Aa and 29Ba for fixing the position of a flat electrode assembly 11 and a battery outer can 12 by contacting with an insulating sheet 32 on at least one of a positive electrode collector member 16 and a negative electrode collector member 18. The insulating sheet 32 is provided between the projections 29Aa, 29Ba and the battery outer can 12. Tips 29Ab and 29Bb of the projections 29Aa and 29Ba project from the flat electrode assembly 11 towards the battery outer can 12 side. The height of the projections is smaller than the thickness of the insulating sheet 32. This prevents short-circuiting between the positive electrode collector member or the negative electrode collector member, and the battery outer can. Thus, a prismatic battery suitable for EVs and HEVs with excellent safety can be obtained.