Welded Cushion Sheet Spacer for Battery Impact Protection
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Solution Overview
Problem
Existing energy storage devices face challenges in preventing internal short-circuiting during impacts due to high manufacturing costs and cumbersome assembly processes, particularly with cushion sheets that are unstable and difficult to position accurately.
Innovation Solution
The energy storage device incorporates a cushion sheet welded to a spacer, providing accurate placement and enhanced stability, which disperses impact forces and prevents short-circuiting, while using materials like polypropylene for easy welding and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a projecting portion is formed on the lid body to disperse impact, then impact absorption is improved, but manufacturing cost increases and material selection is restricted
Solution Approach 1:
The patent introduces a cushion sheet as an intermediary component between the electrode assembly and the lid body's projecting portion. This cushion sheet (made of foam material) serves as a mediator that provides impact absorption functionality without requiring the lid body itself to have complex projections, thereby reducing manufacturing cost and material restrictions while maintaining reliability.
2Reliability
If a separate spacer with projecting portion is used, then impact dispersion is improved, but assembly complexity increases
Solution Approach 1:
The patent merges the cushion sheet with the spacer structure by providing a recess portion in the spacer that receives and positions the cushion sheet. This integration reduces the number of separate components and simplifies assembly, as the cushion sheet is incorporated into the spacer assembly rather than being a separate element requiring additional sealing and positioning steps.
3Adaptability or versatility
If a cushion sheet is used without welding, then material selection is flexible, but positioning accuracy deteriorates
Solution Approach 1:
The welding portion acts as an intermediary mechanism that connects the cushion sheet to the spacer. This welding connection provides precise positioning and stable attachment of the cushion sheet while allowing selection of cushion sheet materials that can be welded (such as foam materials with suitable surface properties), thus achieving both positioning accuracy and material flexibility.
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 easy assembly, accurate cushioning, and effective prevention of internal short-circuiting by dispersing impact forces, thereby enhancing the reliability and cost-effectiveness of the energy storage device.
Implementation Method 1
the cushion sheet is disposed between the spacer and the electrode assembly body having cushioning property
Implementation Method 2
the pressure is dispersed to a relatively large area of the projecting portion so that internal short circuiting can be prevented
Implementation Method 3
the cushion sheet is welded to the spacer
Data Source
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AI summary
To provide an energy storage device where internal short circuiting of an electrode assembly can be prevented while ensuring easy assembling of the energy storage device. An energy storage device according to an aspect of the present invention includes: an electrode assembly which has an electrode assembly body formed by stacking a positive electrode plate, a separator and a negative electrode plate, and tabs extending from the positive electrode plate and the negative electrode plate; a case formed of a case body which accommodates the electrode assembly therein and a lid plate which closes the case body; an external terminal fixed to the lid plate and electrically connected to the tab; a spacer disposed between the electrode assembly body and the lid plate and having rigidity; and a porous cushion sheet disposed between the spacer and the electrode assembly body having cushioning property, wherein the cushion sheet is welded to the spacer.