Electrode Terminal Gap Structure for Weld Heat Isolation
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Solution Overview
Problem
Conventional energy storage devices face reliability issues due to heat conduction during welding of bus bars to electrode terminals, leading to deformation of insulating members and compromised airtightness, and there is a challenge in configuring electrode terminals and insulating members to meet various requirements effectively.
Innovation Solution
An energy storage device design featuring a plate-shaped terminal body with a shaft and step, where an insulating member with a terminal support part and convex parts is positioned between the terminal body and the case, forming a gap to prevent heat conduction and ensure stable support, thereby enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the insulating member is disposed directly between the terminal body and the case, then the terminal body is supported stably, but heat from welding conducts to the insulating member causing deformation and compromising airtightness
Solution Approach 1:
The convex part acts as an intermediary element between the terminal body and the insulating member. It creates a localized gap that prevents direct heat conduction from the terminal body to the insulating member during welding, while still allowing the insulating member to provide support through its terminal support part. This mediator structure resolves the contradiction by blocking the harmful heat path while preserving the support function.
Solution Approach 2:
The contact interface between the terminal body and insulating member is segmented into multiple regions: a contact region for support (through the terminal support part) and a non-contact region (gap formed by the convex part) for heat isolation. This segmentation allows different portions of the interface to serve different functions - support and thermal isolation simultaneously.
2Reliability
If a gap is formed between the terminal body and insulating member to prevent heat conduction, then heat-induced deformation is prevented, but the terminal body support stability is reduced
Solution Approach 1:
The gap is not formed uniformly across the entire interface but is localized to specific regions where the convex part projects. The terminal support part maintains contact for support stability, while the convex part creates localized gaps for heat isolation. This local application of the gap resolves the contradiction by providing thermal protection only where needed while preserving support stability.
3Reliability
If the insulating member is made thicker to prevent heat conduction, then heat resistance is improved, but the device size increases and energy density decreases
Solution Approach 1:
The heat blocking function is extracted from the insulating member's bulk material and implemented through the convex part structure. Instead of increasing the insulating member thickness to block heat, the convex part creates an air gap that provides thermal isolation. This extracts the heat blocking function from the material volume and implements it through geometric configuration, maintaining compact device size.
4Volume of moving object
If the insulating member is made thinner to reduce device size, then volume is reduced, but heat conduction increases causing insulating member deformation
Solution Approach 1:
The convex part serves as a thermal mediator that blocks heat conduction paths without requiring increased insulating member thickness. It creates localized gaps that prevent heat from reaching the insulating member during welding, allowing the use of thinner insulating members while maintaining heat resistance and preventing deformation.
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 prevents heat-induced failures of the insulating member during welding, maintains airtightness, and stabilizes the terminal body, resulting in a more reliable energy storage device with improved energy density and reduced manufacturing costs.
Implementation Method 1
A gap is formed on a side of the convex part between the terminal body and the insulating member when viewed from the projecting direction of the convex part... prevents heat-induced failures of the insulating member during welding
Data Source
AI summary
An energy storage device includes: a case; an electrode terminal having a terminal body, a shaft, and a step disposed at the root of the shaft; and an upper insulating member disposed between the terminal body and the case. The upper insulating member has a terminal support part abutting on a terminal bottom surface of the step and a wall part facing the end face of the terminal body. On one of the terminal body and the upper insulating member, a convex part projecting toward the other of the terminal body and the upper insulating member is formed at a position between the step and the wall part. A gap is formed between the terminal body and the upper insulating member on the side of the convex part.