Secondary Battery One-Unit Cap Assembly Integration
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Solution Overview
Problem
The assembly process of secondary batteries is complex and prone to defects due to the numerous individual assembly processes involved, leading to increased time and inaccuracies.
Innovation Solution
A secondary battery design that integrates a cylindrical can, an electrode assembly, a one-unit cap, and an insulating gasket, where the one-unit cap includes a current interrupt unit, a PTC device, and an adhesive unit to simplify assembly by reducing the number of components and processes, using a double-sided adhesive tape to attach these components securely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate components are assembled individually, then each component can be optimized separately, but the overall assembly process time increases and assembly accuracy decreases
Solution Approach 1:
The patent combines the cap body, current interrupt unit, and PTC device into a single integrated one-unit cap structure. This merging of previously separate components reduces the number of assembly steps, thereby decreasing assembly process time and minimizing assembly errors while maintaining the functional optimization of each component.
Solution Approach 2:
The one-unit cap structure performs multiple functions simultaneously: it seals the battery, provides current interruption safety, and offers thermal protection through the PTC device. By integrating these functions into a single component unit, the patent reduces assembly complexity and improves manufacturing precision without sacrificing component optimization.
2Reliability
If multiple separate components are assembled individually, then each component can be optimized separately, but the number of assembly processes increases leading to more defects
Solution Approach 1:
The patent integrates the cap body, current interrupt unit, and PTC device into a single one-unit cap structure, reducing the number of separate assembly processes. This merging reduces the opportunities for assembly defects while maintaining the reliability benefits of having separate optimized components for each function.
3Adaptability or versatility
If multiple separate components are used, then each component can be optimized for its specific function, but the overall device complexity increases
Solution Approach 1:
The patent combines multiple functionally optimized components (cap body, current interrupt unit, PTC device) into a single integrated one-unit cap structure. This approach maintains the functional optimization of each component while reducing the overall number of separate parts and simplifying the device structure.
Solution Approach 2:
The one-unit cap structure serves as a multi-functional component that simultaneously provides sealing, current interruption, and thermal protection functions. This universality reduces device complexity by eliminating the need for multiple separate components while preserving the functional optimization of each safety mechanism.
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 design reduces assembly time and errors, minimizing defects by integrating key components into a single assembly unit, thereby enhancing the efficiency and reliability of the secondary battery manufacturing process.
Implementation Method 1
an adhesive unit mechanically attaching the current interrupt unit to the cap-up to integrate the current interrupt unit, the PTC device, and the cap-up with each other
Implementation Method 2
an insulating gasket sealing a space between the cylindrical can and the one-unit cap to seal the inside of the cylindrical can
Implementation Method 3
a separator disposed between the first electrode and the second electrode to insulate the first electrode from the second electrode
Data Source
AI summary
A secondary battery includes a can having an opening at a side thereof, an electrode assembly inside the can, the electrode assembly including a first electrode, a second electrode, and a separator disposed between the first electrode and the second electrode, a one-unit cap covering the opening of the can, the one-unit cap including a current interrupt unit, a cap-up on the current interrupt unit, a positive temperature coefficient (PTC) device between the current interrupt unit and the cap-up, and an adhesive unit attaching the current interrupt unit to the cap-up to integrate the current interrupt unit, the PTC device, and the cap-up with each other, and an insulating gasket sealing a space between the can and the one-unit cap to seal the can.