Separator Short-Circuit Induction Layer for Micro Battery Fault Testing

Solution Overview

Problem

Conventional methods for testing internal short circuits in secondary batteries are inefficient, as they require physical deformation of the battery structure, are costly, and cannot precisely simulate micro short circuits, leading to inaccurate evaluations.

Innovation Solution

A secondary battery with a short circuit induction member featuring a metal pattern layer and insulating wax is used, where the metal pattern layer is formed on the separator and covered with insulating wax, allowing for precise induction of internal short circuits without physical deformation, enabling accurate microscopic evaluation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional methods are used to test internal short circuits, then the battery structure must be physically deformed or disassembled, but this increases device complexity and manufacturing cost while reducing measurement precision

Engineering Contradiction:

Improvemeasurement precisionVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The short circuit induction member is pre-installed on the separator during battery manufacturing, positioned exactly where short circuit induction is needed. This preliminary placement eliminates the need for later structural deformation or disassembly, allowing precise micro short circuit testing while maintaining battery integrity and reducing device complexity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The short circuit induction member acts as an intermediary device between the separator and electrodes. It provides a controlled interface for inducing short circuits without requiring physical deformation of the battery structure, thereby enabling precise measurement while avoiding the complexity of mechanical modification

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If physical deformation methods are used to induce short circuits, then short circuit testing can be performed, but the battery structure is damaged and measurement precision is reduced

Engineering Contradiction:

Improvemeasurement precisionVSAvoidstructural integrity

Core Design Contradiction:

Measurement precisionVSStrength

Solution Approach 1:

The short circuit induction member is pre-installed on the separator during battery manufacturing, positioned exactly where short circuit induction is needed. This preliminary placement eliminates the need for later structural deformation or disassembly, allowing precise micro short circuit testing while maintaining battery integrity and reducing device complexity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces mechanical deformation methods with a chemical/electrical induction mechanism. The short circuit induction member uses electrochemical reactions or electrical fields to induce short circuits, substituting the need for physical force and structural deformation, thereby preserving battery strength while enabling precise measurement

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If conventional short circuit testing methods are used, then testing can be performed, but the process is costly and cannot precisely simulate micro short circuits

Engineering Contradiction:

Improveshort circuit induction precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The short circuit induction member is pre-installed on the separator during battery manufacturing, positioned exactly where short circuit induction is needed. This preliminary placement eliminates the need for later structural deformation or disassembly, allowing precise micro short circuit testing while maintaining battery integrity and reducing device complexity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The short circuit induction member creates a simplified, controlled model of actual short circuit conditions. Instead of using complex, expensive real-world failure scenarios, the invention uses a standardized induction member that replicates essential short circuit characteristics, enabling precise manufacturing at lower costs

Inventive Principle:

Principle #26Copying

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 approach allows for precise testing of internal short circuits without disassembling the battery, improving measurement precision and enabling fine-level evaluation of battery safety.

Implementation Method 1

heating the insulation wax disposed on the inside short circuit induction member, thereby inducing an internal short circuit inside the battery

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20240030503A1Secondary battery for testing short circuit, method of manufacturing the secondary battery, and method of evaluating safety of secondary battery

Publication Date: 2024.01.25 LG ENERGY SOLUTION LTD

AI summary

A secondary battery for testing internal short circuit, a method of manufacturing the same, and a method of evaluating safety of a battery using the same are provided. The secondary battery includes a short circuit induction member which is formed on a separator and includes a finely patterned metal pattern layer and an insulating layer configured to cover the metal pattern layer. The secondary battery provides precise implementation of a micro short circuit by finely adjusting a pattern width of the metal pattern layer, and ease of evaluating safety of a battery with respect to an internal short circuit without conventional reassembling a secondary battery, as the secondary battery is assembled using the separator including the short circuit induction member.