Prismatic Battery Lateral Insertion With Bent Tab Insulation

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Solution Overview

Problem

The assembly of prismatic secondary batteries with increased electrode assembly size is difficult due to reduced internal space, making it challenging to insert the electrode assembly into the case effectively.

Innovation Solution

A secondary battery design where the electrode assembly is laterally inserted into a case with a bent electrode tab, featuring a terminal connection, electrode plate insulating member, and a bent portion insulating member to facilitate easy assembly and maximize space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the electrode assembly size is increased to increase battery capacity, then the battery capacity is improved, but the volume of excess space inside the case is reduced making assembly difficult

Engineering Contradiction:

Improvebattery capacityVSAvoidassembly difficulty

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The insulating member is divided into multiple segments: a first insulating member positioned between the electrode assembly and terminal, and a second insulating member positioned between the electrode assembly and cover. This segmentation allows each insulating component to be independently positioned and sized, facilitating easier assembly while maintaining electrical insulation for larger electrode assemblies.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating members are pre-positioned within the case before the electrode assembly is inserted. This preliminary placement of insulating components prepares the assembly path and final position, making it easier to insert larger electrode assemblies without requiring complex adjustment during assembly.

Inventive Principle:

Principle #10Preliminary action

2Quantity of substance

If the electrode assembly size is increased to increase battery capacity, then the battery capacity is improved, but the internal space utilization becomes challenging

Engineering Contradiction:

Improvebattery capacityVSAvoidspace utilization

Core Design Contradiction:

Quantity of substanceVSVolume of moving object

Solution Approach 1:

The insulating members are strategically positioned at specific locations where electrical insulation is needed: between the electrode assembly and terminal, and between the electrode assembly and cover. This localized placement provides necessary insulation without occupying excessive space, allowing larger electrode assemblies to fit efficiently within the case while maintaining safety requirements.

Inventive Principle:

Principle #3Local quality

3Reliability

If insulating members are added to ensure electrical insulation, then the safety is improved, but the device complexity increases

Engineering Contradiction:

Improveelectrical insulationVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating members serve multiple functions simultaneously: they provide electrical insulation between conductive components, act as spacing elements to maintain proper positioning, and facilitate the assembly process by being pre-positioned in the case. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in structural complexity while improving safety.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4672396A1Secondary battery including electrode assembly laterally inserted into case, and manufacturing method thereof

Publication Date: 2025.12.31 SAMSUNG SDI CO LTD

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AI summary

A secondary battery includes: a case having an open side surface; an electrode assembly inserted into the case through the open side surface, the electrode assembly including a bent electrode tab; a terminal electrically connected to the electrode tab of the electrode assembly and exposed to an outside of the case; a cover covering the open side surface of the case; an electrode plate insulating member electrically insulating an electrode plate of the electrode assembly from the terminal; and a bent portion insulating member electrically insulating an inner surface of the cover from the bent portion of the electrode tab.