Prismatic Cell Insulation Sheet Design for Height Control
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Solution Overview
Problem
Existing prismatic cell technologies face issues with height variation, manufacturing cost, insufficient impact strength, and susceptibility to short circuits due to dew condensation, particularly when using insulating films that increase cell height or have weak oxide coatings.
Innovation Solution
A prismatic cell design featuring a prismatic outer can covered on side surfaces and the entire bottom with a folded insulation sheet, where the insulation sheet's edges are positioned above the bottom to prevent water ingress and ensure even height, using a heat-welding film fixed with heat-welding or adhesive methods to maintain insulation and prevent thermal damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin film is used to cover the outer can for insulation, then insulation performance is improved, but the folding portion increases cell height and causes height variation
Solution Approach 1:
The insulation sheet is positioned to extend beyond the bottom surface of the outer can in the vertical dimension, allowing the folded portion to be located above the bottom rather than at the bottom. This dimensional repositioning eliminates height increase while maintaining insulation coverage on the outer can surface.
2Reliability
If oxide coating is used for insulation, then insulation is provided, but the coating has weak impact strength and may peel off
Solution Approach 1:
A flexible insulation sheet made of resin material is used to cover the outer can, replacing the brittle oxide coating. The insulation sheet provides both insulation and impact resistance, as it can absorb impact without peeling off like the oxide coating.
3Reliability
If insulating film is added to cover outer can, then short circuit prevention is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The insulation sheet is folded into specific regions (first region covering bottom, second region covering side surface, third region folded back on side surface). This segmentation allows simple manufacturing processes for each region while achieving complete insulation coverage, avoiding complex manufacturing.
4Area of stationary object
If insulation sheet edges are positioned at bottom, then coverage is maximized, but water ingress occurs causing short circuits
Solution Approach 1:
The insulation sheet is folded to extend beyond the bottom surface and form a barrier that prevents water from reaching the bottom of the outer can. This preliminary protective structure blocks the harmful effect of water ingress before it can cause short circuits, while maintaining full insulation coverage.
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
This configuration ensures reliable insulation, prevents short circuits from dew condensation, maintains even cell height, and reduces manufacturing costs by avoiding complex material combinations, thereby enhancing the efficiency and reliability of assembled battery production.
Implementation Method 1
using a heat-welding film fixed with heat-welding or adhesive methods to maintain insulation and prevent thermal damage
Data Source
AI summary
The present invention aims to provide a method for insulatively covering the side surfaces and bottom of a prismatic outer can in a simple manner. This can be realized by adopting the following configuration: a prismatic cell including a prismatic outer can having an opening at the top thereof; a sealing body for sealing the opening; and positive and negative electrode external terminals that are protruded from and insulated from the sealing body, wherein the prismatic outer can is covered on the side surfaces and entire bottom with a piece of folded insulation sheet. Preferably, the bottom of the prismatic outer can is covered with only one piece of the insulating sheet, and all edges of the insulating sheet is positioned above the bottom of the outer can.