Stacked Secondary Battery Separator Layout for Impact and Vibration Protection
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Solution Overview
Problem
The enlargement of secondary batteries to increase the cruising distance of battery electric vehicles leads to increased weight of the electrode body, necessitating improved protection against impact and vibration to enhance reliability.
Innovation Solution
A secondary battery design featuring a stacked-type electrode body with a zigzag-bent separator and a wound part, accompanied by an insulating sheet covering the separator overlap areas, to provide enhanced protection against damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the size of the secondary battery is enlarged to increase cruising distance, then the energy capacity is improved, but the weight of the electrode body increases
Solution Approach 1:
The separator is divided into multiple functional zones: a zigzag-bent part for spacing, a wound part for securing, and an insulating sheet for protection. This segmentation allows each part to perform its specific function efficiently, enabling the battery to achieve higher energy capacity through better space utilization without proportionally increasing weight.
Solution Approach 2:
The separator transitions from a flat two-dimensional structure to a three-dimensional configuration with zigzag bending and winding. This dimensional change enables the separator to provide mechanical support, electrode positioning, and damage prevention functions simultaneously, allowing the battery to be enlarged for higher capacity without linearly increasing the weight of protective structures.
2Use of energy by moving object
If the weight of the electrode body is increased, then the energy capacity is improved, but the susceptibility to impact and vibration damage increases
Solution Approach 1:
The insulating sheet is placed in advance at the separator overlap part to provide protective cushioning before impact or vibration occurs. This pre-positioned protection prevents electrode damage during battery operation, allowing the battery to achieve higher energy capacity without proportionally increasing vulnerability to mechanical damage.
Solution Approach 2:
The insulating sheet acts as an intermediary element between the separator and the electrode plates. It mediates the mechanical stresses from impact and vibration, preventing direct contact between the separator and electrodes that could cause damage. This allows the battery to be enlarged for higher capacity while maintaining reliability through the intermediary protective layer.
3Reliability
If a zigzag-bent separator is used to improve electrode protection, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The separator is designed as a multi-functional component that simultaneously provides spacing between electrodes, mechanical support through zigzag bending, securement through winding, and protection through the insulating sheet. This universality allows the battery to achieve high reliability through a single integrated structure rather than multiple separate protective components, thereby reducing overall device complexity.
Solution Approach 2:
The insulating sheet is merged with the separator structure at the overlap part, combining the protective function with the structural function in a single integrated design. This merging eliminates the need for separate protective components, reducing device complexity while maintaining high reliability through the combined structure that protects electrodes from damage.
4Reliability
If an insulating sheet is added to cover the separator overlap part, then the electrode protection is improved, but the device complexity increases
Solution Approach 1:
The insulating sheet is strategically placed only at the separator overlap part where it is most needed, merging the protective function with the existing separator structure. This targeted approach provides maximum electrode protection with minimal additional components, avoiding the need to wrap the entire battery in protective material and thereby limiting the increase in device complexity.
Solution Approach 2:
The insulating sheet is applied locally at the separator overlap part rather than uniformly across the entire battery structure. This local quality approach provides enhanced protection precisely where the electrodes are most vulnerable to damage from separator movement, achieving high reliability without the complexity of comprehensive protective coverage throughout the battery.
Data Source
AI summary
A secondary battery includes: a stacked-type electrode body that includes first electrode plates, second electrode plates, and a separator with a band-like shape; and an insulating sheet. The separator includes a zigzag-bent part that is bent in a zigzag manner, and a wound part that is wound to an outer periphery of a part where the first electrode plates, the second electrode plates, and the zigzag-bent part are stacked. The zigzag-bent part includes a first bent part that is disposed on one side in a direction perpendicular to a stacking direction of the first and second electrode plates, and a second bent part that is disposed on the other side in that direction. A separator overlap part where the wound part overlaps twice or more is provided outside the first bent part. The insulating sheet is disposed on an outer surface side of the separator overlap part.