Prismatic Secondary Battery Insulator Layout for Tab Protection
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Solution Overview
Problem
Prismatic secondary batteries experience internal fluctuations of the electrode assembly due to external impacts, leading to stress concentration on electrode tabs, which can result in tab tears, electrical shorts, and reduced battery capacity and reliability.
Innovation Solution
The implementation of upper and lower insulators that occupy the spaces between the case and the electrode assembly, specifically designed to suppress front-to-back and side-to-side fluctuations, improving the support structure and preventing tab damage by filling the gaps between the case and the electrode assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If clearance space is provided between the electrode assembly and the case for electrical connection and electrolyte, then ease of assembly and electrical connection are improved, but the electrode assembly becomes susceptible to fluctuation and slip under external impact
Solution Approach 1:
The patent introduces insulators as intermediary components between the electrode assembly and the case. These insulators fill the clearance space while providing mechanical support and preventing direct contact, thus maintaining ease of assembly while eliminating fluctuation and slip issues.
Solution Approach 2:
The patent divides the clearance space into multiple regions by positioning insulators at specific locations (front, back, left, right surfaces). This segmentation allows the space to serve multiple functions: maintaining electrical connection accessibility, accommodating electrolyte, and preventing electrode assembly movement in different directions.
2Device complexity
If the electrode assembly is supported primarily by tabs connected to terminals, then structural simplicity is improved, but stress concentration on tabs leads to tears, shorts, and reduced reliability
Solution Approach 1:
The patent applies preliminary action by pre-installing insulators that provide support to the electrode assembly before external impacts occur. This preliminary support structure prevents stress from concentrating on the tabs during operation, thereby preventing tab tears and electrical shorts before they can happen.
3Reliability
If insulators are added to occupy spaces and suppress fluctuation, then reliability and safety are improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The insulators serve multiple functions simultaneously: they provide mechanical support to prevent fluctuation, maintain electrical insulation, accommodate the electrolyte volume, and facilitate assembly by being pre-installed in the case. This multi-functionality reduces the need for additional separate components.
Data Source
AI summary
Provided is a prismatic secondary battery, in one example the prismatic secondary battery including: a case including an opening; an electrode assembly stored within the case; and a cap plate coupled to the opening in the case, and having electrode terminals of a positive electrode and a negative electrode, and is provided with at least one of: an upper insulator occupying a first space between the cap plate and an upper surface of the electrode assembly, and a second space between the case and at least two opposing surfaces among front, back, left and right surfaces of the electrode assembly, and a lower insulator occupying a third space between a bottom surface of the case and a lower surface of the electrode assembly, and a fourth space between the case and at least two opposing surfaces among the front, back and left surfaces of the electrode assembly.