Prismatic Battery Insulating Frame Design
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Solution Overview
Problem
Prismatic batteries face a challenge in maintaining high volume energy density due to the need for clearance to prevent internal short circuits, which increases battery size, and existing insulating solutions like resin tape have low mechanical strength and are costly.
Innovation Solution
A prismatic battery design featuring an electrode group with exposed ends covered by an angled U-shaped insulating frame made of a resin sheet, which protects the electrodes and prevents short circuits without adding extra space, using materials like polypropylene, polyethylene, or polyether ether ketone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clearance is provided between the flattened electrode group and the inner wall of the metal outer can to prevent internal short circuit, then the reliability is improved, but the volume energy density decreases
Solution Approach 1:
The insulating frame utilizes the thickness dimension of the electrode group by extending insulating projections from the insulating sheet in the thickness direction. This allows the insulating structure to occupy the existing clearance space rather than requiring additional volume, thus preventing short circuits without compromising volume energy density.
Solution Approach 2:
The insulating frame is constructed from a thin insulating sheet material that can be flexibly formed into a frame structure with projections. This thin-film approach provides effective insulation without adding significant volume, allowing the battery to maintain high volume energy density while ensuring reliable prevention of internal short circuits.
2Reliability
If resin tape is used to insulate the periphery of the flattened electrode group, then the internal short circuit is prevented, but the manufacturing cost increases and mechanical strength is low
Solution Approach 1:
The insulating frame is segmented into a base insulating sheet with multiple insulating projections extending from it. Each projection can be independently positioned to contact specific components (electrode substrates, current collectors, or outer can), providing targeted insulation where needed while using less material than complete wrapping, thus reducing cost and improving mechanical strength.
Solution Approach 2:
The insulating frame combines a flat insulating sheet with three-dimensional projections formed from the same material or complementary materials. This composite structure integrates both the flexibility of a sheet and the mechanical strength of protruding elements, creating a more robust insulating solution than simple resin tape while maintaining ease of manufacture.
Data Source
AI summary
According to an embodiment of the invention, a prismatic battery includes an electrode group 10 contained in a prismatic metal outer can. The electrode group 10 has a positive electrode substrate exposed part 11 at one end and a negative electrode substrate exposed part 12 at the other end. The positive and negative electrode substrate exposed parts 11 and 12 are bundled and welded to positive and negative electrode current collectors 13 and 14, respectively. The positive electrode substrate exposed part 11 and positive electrode current collector 13 and the negative electrode substrate exposed part 12 and negative electrode current collector 14 are covered with an insulating frame 16 having an angled U-shaped cross section and an angled U-shaped outline. It is therefore possible to provide a prismatic battery of a simple structure including an electrode group whose ends are covered with an easily manufactured insulating cover in which the battery's volume energy density is maintained and an internal short circuit is prevented.