Battery cover, battery cell, vehicle, method of producing a battery cover, and use

Abstract

The present invention relates to a battery cover, a battery cell, a vehicle, a method of producing a battery cover and a use. The battery cover (1) comprises: an upper insulating portion (2); a lower insulating portion (3); and a substrate (4) disposed between the upper insulating portion (2) and the lower insulating portion (4); wherein the lower insulating portion (3) comprises a pair of cavities (3c) on an upper surface (3d), and the substrate (4) comprises a pair of protrusions (4a) on a bottom surface (4b), and the pair of protrusions (4a) of the substrate (4) match the pair of cavities (3c) of the lower insulating portion (3).

Description

Technical Field

[0001] The present invention relates to a battery cover, a battery cell including a battery cover, a vehicle including an energy storage device containing a battery cell, a method for producing a battery cover, a battery cover obtainable by the method, and the use of a battery cover for maintaining the mechanical stability of a battery cell. Background Technology

[0002] Battery cell housings, particularly rechargeable (secondary) battery cell housings, include a battery outer casing such as a prismatic battery casing and two covers that hermetically seal the battery cell (a positive cover at the cathode and a negative cover at the anode). Each of these covers includes a substrate. The substrate is the portion of the cover sealed to the outer casing via welding (e.g., laser welding). The hermetically sealed battery casing is crucial for battery performance stability and safety. Aluminum is primarily used as the casing and substrate material, resulting in a high weight and / or volume for the battery cell.

[0003] In electric vehicles, such as electric cars, battery cells are connected in series or parallel with other battery cells to form battery packs or modules. To connect the battery cells in series or parallel, a busbar, which is welded to the battery cover, is used. A busbar is a metal strip or rod used to connect the battery cells, thus allowing for efficient power distribution. It acts as a common connection point for multiple battery cells. Busbars typically handle high current loads with minimal resistance and heat generation.

[0004] Typically, a battery cover comprises both conductive and non-conductive components. The function of the non-conductive material is to electrically isolate the battery casing and to seal the casing under pressure (as the battery cells are filled with liquid (electrolyte) and undergo pressure cycling due to chemical processes). The battery cover components are joined by welding and / or pressing, such as by force closure between rivets, sealing rings, and a base plate.

[0005] During the lifecycle of an electric vehicle, battery cells are exposed to continuous vibration and / or impact torque. Furthermore, in the event of a collision, the battery cells need to absorb high forces to some extent. These conditions can cause components of the forcibly sealed battery cover (such as rivets, sealing rings, and substrates) to loosen. Since these components are generally connected by cylindrical and / or circular structures, they are prone to twisting under vibration or impact torque. Twisting can lead to busbar tearing and loosening of the forcibly sealed battery cover components, ultimately resulting in electrolyte leakage. Consequently, functional loss of the battery cell and / or battery module can occur.

[0006] Many attempts have been made to provide new battery cover designs and manufacturing processes to overcome the aforementioned shortcomings.

[0007] CN 218975604 U describes a battery top cover assembly including a lower plastic, a top cover sheet, an upper plastic, and electrodes. The electrodes are provided with anti-torsion sections including protrusions and cavities. However, in CN 218975604U, only the electrodes are provided with anti-torsion sections, while the connection between the lower plastic and the top cover sheet does not include an anti-torsion section. Because the lower plastic and the top cover sheet are connected by a cylindrical and / or circular structural form, they are prone to torsion under impact torque.

[0008] CN 215869575 U describes a battery cover including a cover body, electrodes, an adapter, a sealing member, a first insulating member, a second insulating member, and terminals. An anti-torsion structure is disposed between the second insulating member and the cover body to prevent the second insulating member from rotating about its axis. However, in CN 215869575 U, the anti-torsion structure is disposed at the periphery of the cover body, rather than at its center. Under impact torque, particularly extreme impact torque during a car crash, a large force is applied to the unprotected center of the cover body, causing tearing of the battery cover.

[0009] WO 2018026728 A1 describes a cover assembly for a prismatic battery cell, wherein the cover assembly includes a cover, terminals projecting through the cover, a current collector electrically coupled to the terminals, and an overcharge protection component disposed between the terminals and the current collector. However, the cover assembly in WO 2018026728A1 does not provide anti-torsion protection.

[0010] CN 217158383 U describes a top cover assembly including an electrode sheet, a top cover sheet, an electrode plate, first and second plastic bodies, and a sealing member. The top cover assembly further includes an anti-torsion structure with a circular anti-torsion hole included in the top cover sheet and an anti-torsion portion included in the electrode sheet. However, such cylindrical and / or circular structural forms are prone to torsion under impact torques, particularly extreme impact torques such as those during a vehicle collision. Furthermore, the anti-torsion structure is located at the periphery of the top cover assembly, causing the assembly to tear under impact torques, particularly extreme impact torques at the center of the top cover assembly.

[0011] The common thread in all the literature is that the battery cover exhibits an insufficient structural integrity for achieving optimal torsional resistance under constant vibration and / or impact torque, particularly extreme impact torque. While the battery covers in the aforementioned literature include torsional resistance structures, they also contain weak points and potential crack areas, especially at the center of the cover.

[0012] Considering sustainability, energy conservation, and safety issues, there is an urgent need to develop battery cells with battery covers that have high mechanical stability. Summary of the Invention

[0013] Surprisingly, it has been found that the specific structure of the battery cover, including paired protrusions and paired cavities, avoids weak areas that can be twisted and cracked, thereby improving the overall safety of the battery cell. Furthermore, due to the specific arrangement of the protrusions and cavities along the battery cover components, the battery cover structure has a so-called "foolproof" design, making manual operation more foolproof. In addition, the manufacturing process of the battery cover according to the invention requires minimal energy and time. The specific arrangement of the paired protrusions and paired cavities in the battery cover components ensures uniform strength and stability around the periphery and center of the battery cover, thereby preventing cracking and minimizing twisting during impact moments. During vibration and / or impact moments, a pair of protrusions move uniformly within the cavity, reducing the twisting and mechanical stress distribution throughout the battery cover.

[0014] The object of the present invention is to provide a battery cover, a battery cell, a vehicle, a method for producing a battery cover, and a use of the battery cover that at least partially overcome the above-mentioned disadvantages.

[0015] This objective is achieved by the use of the battery cover according to the first aspect of this disclosure, the battery cell according to the second aspect of this disclosure, the vehicle according to the third aspect of this disclosure, the method according to the fourth aspect of this disclosure, the battery cover according to the fifth aspect of this disclosure, and the battery cover according to the sixth aspect of this disclosure.

[0016] Further advantageous embodiments of the present invention are derived from the following description of preferred embodiments of the present invention.

[0017] A first aspect of the present invention relates to a battery cover comprising:

[0018] - Upper insulating part;

[0019] - Lower insulation portion; and

[0020] - A substrate is disposed between the upper insulating portion and the lower insulating portion;

[0021] The lower insulating portion includes a pair of cavities on the upper surface, and the substrate includes a pair of protrusions on the bottom surface, wherein the pair of protrusions of the substrate mate with the pair of cavities of the lower insulating portion.

[0022] In some embodiments, the present invention relates to a battery cover comprising:

[0023] - Upper insulating part;

[0024] - Lower insulation portion; and

[0025] - A substrate disposed between the upper insulating portion and the lower insulating portion;

[0026] The upper insulating portion includes a pair of protrusions on the bottom surface, the lower insulating portion includes a pair of cavities on the upper surface, and the substrate includes a pair of protrusions on the bottom surface and a pair of cavities on the upper surface opposite to the pair of protrusions. The pair of protrusions of the substrate matches the pair of cavities of the lower insulating portion, and the pair of cavities of the substrate matches the pair of protrusions of the upper insulating portion.

[0027] In the context of this invention, "battery cover" refers to a portion of the battery cell housing. The battery cell housing may include two covers (a positive cover at the positive terminal and a negative cover at the negative terminal) and a battery casing, such as a prismatic battery casing. The two covers provide an airtight seal to the battery casing, thereby preventing electrolyte leakage. The two covers may be welded to the battery casing. The battery casing may be made of a material selected from the group consisting of steel, stainless steel, and / or aluminum.

[0028] In the context of this invention, a "battery cell" refers to a device that generates electrical energy. A battery cell may include an anode (negative electrode), a cathode (positive electrode), an electrolyte, and a battery cell housing. The electrolyte facilitates ion movement between the electrodes.

[0029] In the context of this invention, "battery" refers to a device comprising one or more battery cells. A battery can be a single cell, such as an AA battery, or a multi-cell battery in the form of a battery module or package, such as those used in laptops or electric vehicles.

[0030] upper insulation part

[0031] In the context of this invention, "upper insulating portion" refers to a component of the battery cell cover that provides electrical insulation and / or mechanical protection.

[0032] The upper insulating portion may be a component located between the positive terminal of the battery cell and the substrate of the positive terminal cover, and / or between the negative terminal of the battery cell and the substrate of the negative terminal cover. The upper insulating portion can prevent electrical short circuits by insulating the positive or negative terminal from the battery casing, and / or provide a barrier to protect internal components from mechanical stress or damage.

[0033] The upper insulating portion may include an upper surface and a bottom surface.

[0034] In the context of this invention, "surface" refers to the outermost layer or boundary of a battery cover component exposed to the surrounding environment.

[0035] In some examples, the surface area of ​​the upper surface may be equal to the surface area of ​​the bottom surface of the upper insulating portion. In some other examples, the surface area of ​​the upper surface may be smaller than the surface area of ​​the bottom surface of the upper insulating portion. In some other examples, the surface area of ​​the upper surface of the upper insulating portion may be larger than the surface area of ​​the bottom surface of the upper insulating portion.

[0036] From the top view to the bottom view, the upper insulating portion can be located on the top of the substrate.

[0037] The upper surface of the upper insulating portion can be positioned opposite to the substrate. The bottom surface of the upper insulating portion can be positioned facing the substrate.

[0038] The upper insulating portion includes a pair of protrusions on the bottom surface. In some examples, the upper insulating portion may include more than a pair of protrusions on the bottom surface.

[0039] In some other examples, the upper insulating portion may include a pair of protrusions on the bottom surface and a pair of cavities on the upper surface. The pair of cavities may be opposite to the pair of protrusions.

[0040] In some other examples, the upper insulating portion may include more than one pair of protrusions on the bottom surface and more than one pair of cavities on the upper surface opposite to the pair of protrusions.

[0041] Each of the pair of protrusions in the upper insulating portion may have a shape selected from a circular shape, a rectangular shape, a square shape, a triangular shape, or an elliptical shape. Each of the pair of cavities in the upper insulating portion may have a shape selected from a circular shape, a rectangular shape, a square shape, a triangular shape, or an elliptical shape, wherein the shape of each cavity in the pair of cavities may be equal to the shape of each of the pair of protrusions on the upper surface.

[0042] Each of the pair of protrusions in the upper insulating portion can protrude outward from the bottom surface of the upper insulating portion.

[0043] In the context of this invention, "projecting outward from the bottom surface" means that the protrusion extends or protrudes above the horizontal level of the bottom surface. The protrusion may not be flush with the bottom surface, but may rise and extend away from the bottom surface, thereby creating a bulge in the surface. The bottom surface may be a flat plane, while the protrusion may extend or protrude above the horizontal level of the bottom surface.

[0044] In most examples, each of the pair of protrusions in the upper insulating portion may have a circular shape.

[0045] In some examples, when viewed in a cross-sectional view, each of a pair of protrusions in the upper insulation portion may include a protrusion height and a protrusion width, wherein the ratio of the protrusion height to the protrusion width of a single protrusion may be from 0.1 to 2. For all protrusions in the upper insulation portion, the protrusion height and protrusion width may be equal.

[0046] In some examples, each of a pair of protrusions in a circular upper insulating portion may include a radius of 1.5-12 mm, a diameter of 3-24 mm corresponding to the width of the protrusion, and an outer diameter of 3-24 mm.

[0047] The height of the protrusion can be the distance between the top and bottom surfaces of the protrusion. The height of the protrusion can range from 0.05 mm to 5 mm. In some examples, the height of the protrusion can range from 0.1 to 2.5 mm.

[0048] In the context of this invention, "protruding top surface" refers to the uppermost surface of a protrusion that extends outward from the bottom surface of the upper insulating portion. When viewed in cross-section, the protruding top surface may be the highest part of the protrusion.

[0049] In the context of this invention, "protrusion width" refers to the horizontal length of the top surface of the protrusion when viewed in a cross-sectional view. The protrusion width can be from 0.1 mm to 5 mm. In some examples, the protrusion width can be from 0.1 mm to 2.5 mm.

[0050] In some other examples, the protrusion may include a larger width adjacent to the bottom surface and a smaller width at the top surface. In these examples, the protrusion may narrow from the top surface to the top surface.

[0051] In some examples, when viewed in a cross-sectional view, each of the pair of protrusions in the upper insulating portion includes two corners at the top surface. The two corners can be rounded or sharp. The two corners can have an angle of 90° or greater.

[0052] The upper surface of the upper insulating portion may be opposite to the bottom surface of the upper insulating portion. The upper surface may include a pair of cavities opposite to a pair of protrusions on the bottom surface of the upper insulating portion. This means that the pair of cavities may reflect the shape and position of the pair of protrusions on the bottom surface of the upper insulating portion.

[0053] In most examples, each of the pair of cavities in the upper insulating portion may have a circular shape.

[0054] Each of the pair of cavities in the upper insulating portion may include a cavity depth, a cavity bottom width, and a cavity opening width.

[0055] The cavity depth can be the distance between the bottom surface of the cavity and the cavity entrance. In the context of this invention, the "bottom surface of the cavity" refers to the surface inside the cavity, which, when viewed in cross-section, is located at the deepest part of the cavity. In the context of this invention, the "cavity entrance" is the highest part of the cavity when viewed in cross-section.

[0056] In some examples, each of the pair of cavities in the upper insulating portion includes a cavity bottom width and a cavity opening width, wherein the ratio of the cavity bottom width to the cavity opening width may be 0.1 to 2.

[0057] In the context of this invention, "cavity bottom width" refers to the horizontal distance passing through the bottom surface of the cavity. It is a measurement of the width at the deepest part of the cavity. When the cavity has a circular shape, the cavity bottom width may correspond to the diameter of the cavity at the bottom. When the cavity has a rectangular or square shape, the cavity bottom width may correspond to the diagonal of the cavity at the bottom.

[0058] In the context of this invention, "cavity opening width" refers to the horizontal distance through the cavity entrance. It is a measurement of the width at the highest point of the cavity. When the cavity has a circular shape, the cavity opening width may correspond to the cavity diameter at the entrance. When the cavity has a rectangular or square shape, the cavity opening width may correspond to the diagonal of the cavity at the entrance.

[0059] In some examples, each of the pair of cavities in the upper insulating portion may include a cavity depth of 0.05 mm to 5 mm. In some examples, each of the pair of cavities in the upper insulating portion may include a cavity depth of 0.1 mm to 2.5 mm.

[0060] In some examples, each of the pair of cavities in the upper insulating portion may include a cavity bottom width of 0.05 mm to 36 mm. In some examples, the cavity bottom width may be 0.05 mm to 36 mm.

[0061] In some examples, each of the pair of cavities in the upper insulating portion may include a cavity opening width of 0.06 mm to 40 mm. In some examples, the cavity bottom width may be 0.06 mm to 40 mm.

[0062] In some examples, the ratio of the height of each of the protrusions in a pair of protrusions in the upper insulating portion to the depth of each corresponding cavity in a pair of cavities in the upper insulating portion may be in the range of 1 to 1.25.

[0063] In some examples, the width of each of a pair of protrusions in the upper insulating portion may be equal to the cavity opening width of the corresponding cavity on the upper surface. In other examples, the protrusion width may be greater than the cavity opening width of the corresponding cavity on the upper surface of the upper insulating portion.

[0064] In some examples, the opening width of each cavity in a pair of cavities in the upper insulating portion may be greater than or equal to the bottom width of each cavity in a pair of cavities in the upper insulating portion. In some other examples, the opening width of each cavity in a pair of cavities in the upper insulating portion may be less than the bottom width of each cavity in a pair of cavities in the upper insulating portion.

[0065] In some examples, the ratio of the bottom width of each cavity in a pair of cavities of the upper insulating portion to the opening width of each cavity in a pair of cavities of the upper insulating portion may be 0.1-1.0, and the opening width may be greater than the bottom width.

[0066] In some examples, the cavity width of each of the pair of cavities in the upper insulating portion may decrease continuously from the cavity opening width to the cavity bottom width.

[0067] In some examples, each of the pair of cavities in the upper insulating portion may have a circular shape, wherein the cavity bottom width (diameter) at the bottom of the cavity is 3mm-36mm, the cavity opening width (diameter) at the cavity entrance is 3mm-40mm, the radius at the bottom of the cavity is 0.05mm-3mm, and the radius at the cavity entrance is 0.05mm-3mm.

[0068] In some examples, each of the pair of cavities in the upper insulating portion may have a rectangular or square shape, wherein the cavity bottom width (diagonal length) at the bottom of the cavity is 5mm-80mm, and the cavity opening width (diagonal length) at the entrance of the cavity is 5mm-100mm.

[0069] In some examples, each of the pair of cavities in the upper insulating portion may include four corners in a cross-sectional view: two entrance corners at the cavity entrance and two bottom corners at the bottom surface of the cavity. The two entrance corners may be rounded or sharp. The two bottom corners may be rounded or sharp. The four corners of each of the pair of cavities in the upper insulating portion may include angles of 90° or greater.

[0070] The upper insulating portion may additionally include a central hole. The hole may be adapted to be penetrated by rivets or poles of the battery cell. The hole may be closed by terminals and / or metal caps.

[0071] The upper insulating portion can be rectangular or square in shape. The upper insulating portion can have a length of 1cm-12cm, a width of 1cm-8cm, and a diagonal of 1cm-14cm. The diagonal of a rectangle or square is a line segment connecting two opposite sides of the rectangle or square.

[0072] In the context of this invention, the center of a rectangular or square upper insulating portion refers to the point or area at the intersection of the diagonals of the rectangular or square upper insulating portion. The center may be equidistant from all four edges of the upper insulating portion.

[0073] In some examples, the four edges of the upper insulation portion may be rounded. In other examples, the four edges of the upper insulation portion may be sharp.

[0074] In some examples, each of the pair of protrusions in the upper insulating portion may be arranged symmetrically about the center of the upper insulating portion. In some examples, each of the pair of cavities in the upper insulating portion may be arranged symmetrically about the center of the upper insulating portion. This means that each of the pair of protrusions and / or each of the pair of cavities in the upper insulating portion may be equidistant from the center of the upper insulating portion.

[0075] In some examples, for one of the two battery cell covers, one of the protrusions of the upper insulating portion and / or one of the cavities of the upper insulating portion may be eccentric. Such an arrangement allows for the failure-protected assembly of the negative and positive battery covers, since one battery cover may include an eccentric arrangement of protrusions and / or cavities (foolproof design).

[0076] In some examples, for one of the two battery cell covers, one of the protrusions of the upper insulating portion and / or one of the cavities of the upper insulating portion may have an alternative shape (e.g., rectangular or square) or an alternative size. Such an arrangement can make the assembly of the negative and positive battery covers fail-safe, since one battery cover may include other shapes or sizes of protrusions and / or cavities (foolproof design).

[0077] The upper insulating portion may additionally include a wall surrounding the periphery of the upper insulating portion. The wall may be located on the upper surface of the upper insulating portion. The wall may include a height of 0.1-30 mm and a thickness of 0.1-10 mm. The height of the wall may be the distance between the top surface of the wall and the upper surface of the upper insulating portion.

[0078] In the context of this invention, "top surface of the wall" refers to the uppermost surface of the wall that protrudes outward from the upper surface of the upper insulating portion. When viewed in cross-section, the top surface of the wall may be the highest part of the wall.

[0079] Lower insulation section

[0080] In the context of this invention, "lower insulating portion" refers to a component of the battery cell cover that provides electrical insulation and / or mechanical protection.

[0081] The lower insulation section can prevent electrical short circuits by insulating the rivets, battery stacks and / or battery terminals from the battery casing, and / or provide a barrier to protect internal components from mechanical stress or damage.

[0082] From a top view to a bottom view, the lower insulating portion may be located below the substrate. The lower insulating portion may include a top surface and a bottom surface.

[0083] In some examples, the surface area of ​​the upper surface may be equal to the surface area of ​​the bottom surface of the lower insulation portion. In some other examples, the surface area of ​​the upper surface may be less than the surface area of ​​the bottom surface of the lower insulation portion. In some other examples, the surface area of ​​the upper surface of the lower insulation portion may be greater than the surface area of ​​the bottom surface of the lower insulation portion.

[0084] The upper surface of the lower insulating portion can be positioned facing the substrate. The bottom surface of the lower insulating portion can be positioned opposite to the substrate.

[0085] The lower insulating portion includes a pair of cavities on the upper surface. In some examples, the lower insulating portion may include more than one pair of cavities on the upper surface.

[0086] In some other examples, the lower insulating portion may include a pair of protrusions on the bottom surface and a pair of cavities on the upper surface. The pair of cavities may be opposite to the pair of protrusions. In some other examples, the lower insulating portion may include more than a pair of protrusions on the bottom surface and more than a pair of cavities on the upper surface opposite to the pair of protrusions.

[0087] Each of the pair of protrusions in the lower insulating portion may have a shape selected from circular, rectangular, square, triangular, or elliptical shapes. Each of the pair of cavities in the lower insulating portion may have a shape selected from circular, rectangular, square, triangular, or elliptical shapes, wherein the shape of each cavity in the pair of cavities may be equal to the shape of each of the pair of protrusions on the upper surface.

[0088] Each of the pair of protrusions in the lower insulation portion may project outward from the bottom surface of the lower insulation portion. The bottom surface may be a flat plane, while the protrusion may extend or protrude above the horizontal level of the bottom surface.

[0089] In most examples, each of the pair of protrusions in the lower insulation portion may have a circular shape.

[0090] In some examples, when viewed in a cross-sectional view, each of a pair of protrusions in the lower insulation portion may include a protrusion height and a protrusion width, wherein the ratio of the protrusion height to the protrusion width of a single protrusion may be 0.5 to 0.7. For all protrusions in the lower insulation portion, the protrusion height and protrusion width may be equal.

[0091] In some examples, each of a pair of protrusions in a circular lower insulating portion may include a radius of 1.5 mm to 12 mm, a diameter of 3 mm to 24 mm corresponding to the width of the protrusion, and an outer diameter of 3 mm to 24 mm.

[0092] The protrusion height can be the distance between the top surface of the protrusion and the bottom surface of the lower insulating portion. The protrusion height can be from 0.05 mm to 5 mm. In some examples, the protrusion height can be from 0.1 mm to 3 mm.

[0093] In the context of this invention, "protrusion width" refers to the horizontal length of the top surface of the protrusion when viewed in a cross-sectional view. The protrusion width can range from 0.1 mm to 5 mm. In some examples, the protrusion width can range from 0.2 mm to 2.5 mm.

[0094] In some other examples, the protrusion may include a larger width adjacent to the bottom surface and a smaller width at the top surface. In these examples, the protrusion may narrow from the top surface to the final surface.

[0095] In some examples, when viewed in a cross-sectional view, each of the pair of protrusions in the lower insulation portion includes two corners at the top surface. These two corners can be rounded or sharp. They can have an angle of 90° or greater.

[0096] The upper surface of the lower insulating portion may be opposite to the bottom surface of the lower insulating portion. The upper surface may include a pair of cavities opposite to a pair of protrusions on the bottom surface of the lower insulating portion. This means that the pair of cavities may reflect the shape and position of the pair of protrusions on the bottom surface of the lower insulating portion.

[0097] In most examples, each of the pair of cavities in the lower insulating portion may have a circular shape.

[0098] Each of the pair of cavities in the lower insulating portion may include a cavity depth, a cavity bottom width, and a cavity opening width.

[0099] In some examples, each of the pair of cavities in the lower insulation portion includes a ratio of 0.1 to 1.0 of the cavity bottom width to the cavity opening width.

[0100] When the cavity has a circular shape, the width of the cavity bottom can correspond to the diameter of the cavity at the bottom. When the cavity has a rectangular or square shape, the width of the cavity bottom can correspond to the diagonal of the cavity at the bottom. When the cavity has a circular shape, the width of the cavity opening can correspond to the diameter of the cavity at the entrance. When the cavity has a rectangular or square shape, the width of the cavity opening can correspond to the diagonal of the cavity at the entrance.

[0101] In some examples, each of the pair of cavities in the lower insulation portion may include a cavity depth of 0.05 mm to 5 mm. In some examples, each of the pair of cavities in the lower insulation portion may include a cavity depth of 0.1 mm to 2.5 mm.

[0102] In some examples, each of the pair of cavities in the lower insulation portion may include a cavity bottom width of 0.05 mm to 100 mm. In some examples, the cavity bottom width may be 0.05 mm to 80 mm.

[0103] In some examples, each of the pair of cavities in the lower insulation portion may include a cavity opening width of 0.06 mm to 100 mm. In some examples, the cavity bottom width may be 0.06 mm to 80 mm.

[0104] In some examples, the ratio of the height of each of the protrusions in a pair of protrusions in the lower insulation portion to the depth of each corresponding cavity in a pair of cavities in the lower insulation portion may be in the range of 1 to 1.25.

[0105] In some examples, the width of each of a pair of protrusions in the lower insulation portion may be equal to the cavity opening width of the corresponding cavity on the upper surface. In other examples, the protrusion width may be greater than the cavity opening width of the corresponding cavity on the upper surface of the lower insulation portion.

[0106] In some examples, the opening width of each cavity in a pair of cavities of the lower insulation portion may be greater than or equal to the bottom width of each cavity in a pair of cavities of the lower insulation portion. In some other examples, the opening width of each cavity in a pair of cavities of the lower insulation portion may be less than the bottom width of each cavity in a pair of cavities of the lower insulation portion.

[0107] In some examples, the ratio of the bottom width of each cavity in a pair of cavities of the lower insulation portion to the opening width of each cavity in a pair of cavities of the lower insulation portion may be 0.1-1.0, and the opening width may be greater than the bottom width.

[0108] In some examples, the cavity width of each of the pair of cavities in the lower insulation portion may decrease continuously from the cavity opening width to the cavity bottom width.

[0109] In some examples, each of the pair of cavities in the lower insulating portion may have a circular shape, wherein the cavity bottom width (diameter) at the bottom of the cavity is 3-60 mm, the cavity opening width (diameter) at the cavity entrance is 3-60 mm, the radius at the bottom of the cavity is 0.05-5 mm, and the radius at the cavity entrance is 0.05-5 mm.

[0110] In some examples, each of the pair of cavities in the lower insulation portion may have a rectangular or square shape, wherein the cavity bottom width (diagonal length) at the bottom of the cavity is 1-140 mm, and the cavity opening width (diagonal length) at the entrance of the cavity is 1-120 mm.

[0111] In some examples, each of the pair of cavities in the lower insulation portion may include four corners in a cross-sectional view: two entrance corners at the cavity entrance and two bottom corners at the bottom surface of the cavity. The two entrance corners may be rounded or sharp. The two bottom corners may be rounded or sharp. The four corners of each of the pair of cavities in the lower insulation portion may include angles of 90° or greater.

[0112] The lower insulation portion may additionally include a central hole. The hole may be adapted to be penetrated by rivets or poles of the battery cell.

[0113] The lower insulation portion may have a rectangular or square shape. The lower insulation portion may have a rectangular shape with a length-to-width ratio of 1:1 to 50:1.

[0114] In the context of this invention, the center of a rectangular or square lower insulating portion refers to the point or area at the intersection of the diagonals of the rectangular or square lower insulating portion. The center may be equidistant from all four edges of the lower insulating portion.

[0115] In some examples, the four edges of the lower insulation portion may be rounded. In other examples, the four edges of the lower insulation portion may be sharp.

[0116] In some examples, each of the pair of protrusions in the lower insulation portion may be arranged symmetrically about the center of the lower insulation portion, and / or each of the pair of cavities in the lower insulation portion may be arranged symmetrically about the center of the lower insulation portion. This means that each of the pair of protrusions in the lower insulation portion and / or each of the pair of cavities in the lower insulation portion may be equidistant from the center of the lower insulation portion.

[0117] In some examples, for one of two battery cell covers, one of the protrusions in the lower insulation portion and / or one of the cavities in the lower insulation portion may be eccentric. Such an arrangement allows for fail-safe assembly of the negative and positive battery covers, since one battery cover may include an eccentric arrangement of protrusions and / or cavities (foolproof design).

[0118] In some examples, for one of the two battery cell covers, one of the protrusions of the lower insulation portion and / or one of the cavities of the lower insulation portion may have an alternative shape (e.g., rectangular or square) or size. Such an arrangement can make the assembly of the negative and positive battery covers fail-safe, since one battery cover may include other shapes or sizes of protrusions and / or cavities (foolproof design).

[0119] The lower insulating portion may additionally include a plurality of rectangular or square segments on the upper surface, wherein the plurality of segments may be located on two opposite edges of the lower insulating portion and may form rectangular or square cavities. In some examples, the lower insulating portion may include three rectangular segments on one edge, wherein the three rectangular segments form three adjacent cavities, and three rectangular segments on opposite edges, wherein the three rectangular segments on opposite edges also form three adjacent cavities. When the lower insulating portion may have a rectangular shape, the plurality of segments may be located on the shorter side of the rectangle.

[0120] On the bottom surface of the lower insulation portion, protrusions may be provided on opposite sides of multiple segments. The size of the protrusions may reflect the size of the multiple segments on the upper surface of the lower insulation portion. The multiple segments and protrusions may be symmetrically positioned around the center of the lower insulation portion.

[0121] The upper plastic insulation portion and / or the lower plastic insulation may be made of plastics selected from the group consisting of polypropylene, polyethylene, polycarbonate, polyamide and / or polyvinyl chloride.

[0122] substrate

[0123] In the context of this invention, "substrate" refers to a structural component of the battery cell cover that facilitates the assembly and / or secure attachment of the cover to a battery casing, such as a prismatic battery cell.

[0124] From the top view to the bottom view, the substrate is located between the upper insulating portion and the lower insulating portion.

[0125] The substrate may include a top surface and a bottom surface opposite to the top surface. The top surface of the substrate may be positioned facing the upper insulating portion and opposite to the battery cell housing. The bottom surface may be positioned facing the battery cell housing and towards the lower insulating portion.

[0126] In some examples, the surface area of ​​the upper surface may be equal to the surface area of ​​the bottom surface of the substrate. In some other examples, the surface area of ​​the upper surface may be less than the surface area of ​​the bottom surface of the substrate. In some still examples, the surface area of ​​the upper surface of the substrate may be greater than the surface area of ​​the bottom surface of the substrate.

[0127] The substrate includes a pair of cavities on its upper surface and a pair of protrusions on its lower surface. The pair of cavities may be opposite to the pair of protrusions. In some other examples, the substrate may include more than one pair of protrusions on its lower surface and more than one pair of cavities on its upper surface opposite to the pair of protrusions.

[0128] Each of the pair of protrusions on the substrate may have a shape selected from a circular shape, a rectangular shape, a square shape, a triangular shape, or an elliptical shape. Each of the pair of cavities on the substrate may have a shape selected from a circular shape, a rectangular shape, a square shape, a triangular shape, or an elliptical shape, wherein the shape of each cavity in the pair of cavities may be equal to the shape of each of the pair of protrusions on the upper surface.

[0129] In some examples, the substrate may not include a pair of cavities opposite to a pair of protrusions.

[0130] Each of a pair of protrusions on the substrate may project outward from the bottom surface of the substrate. The bottom surface may be a flat plane, and the protrusion may extend or protrude above the horizontal level of the bottom surface.

[0131] In most examples, each of the pair of protrusions on the substrate may have a circular shape.

[0132] In some examples, when viewed in a cross-sectional view, each of a pair of protrusions on the substrate may include a protrusion height and a protrusion width, wherein the ratio of the protrusion height to the protrusion width of a single protrusion may be from 0.05 to 10. In some embodiments, the ratio of the protrusion height to the protrusion width of a single protrusion may be from 0.5 to 51. In some other examples, the ratio of the protrusion height to the protrusion width of a single protrusion may be from 0.5 to 50.1. In some examples, the protrusion height and protrusion width may be equal for all protrusions on the substrate.

[0133] In some examples, each of a pair of protrusions on a substrate with a circular shape may include a radius of 1.5 mm to 15 mm, a diameter of 3 mm to 30 mm corresponding to the width of the protrusion, and an outer diameter of 3 mm to 30 mm.

[0134] The protrusion height can be the distance between the top surface of the protrusion and the bottom surface of the substrate. The protrusion height can be from 0.05 mm to 5 mm. In some examples, the protrusion height can be from 0.1 mm to 2.5 mm.

[0135] In the context of this invention, "protrusion width" refers to the horizontal length of the top surface of the protrusion when viewed in a cross-sectional view. The protrusion width can range from 0.1 mm to 30 mm. In some examples, the protrusion width can range from 0.2 mm to 25 mm.

[0136] In some other examples, the protrusion may include a larger width adjacent to the bottom surface and a smaller width at the top surface. In these examples, the protrusion may narrow from the top surface to the final surface.

[0137] In some examples, when viewed in a cross-sectional view, each of the pair of protrusions on the substrate includes two corners at the top surface. These two corners can be rounded or sharp. They can have an angle of 90° or greater.

[0138] The upper surface of the substrate may be opposite to the bottom surface of the substrate. The upper surface may include a pair of cavities opposite to a pair of protrusions on the bottom surface of the substrate. This means that the pair of cavities may reflect the shape and position of the pair of protrusions on the bottom surface of the substrate.

[0139] In most examples, each of the pair of cavities in the substrate may have a circular shape.

[0140] Each cavity in a pair of cavities on the substrate may include a cavity depth, a cavity bottom width, and a cavity opening width.

[0141] In some embodiments, each of a pair of cavities in the substrate includes a cavity bottom width and a cavity opening width, wherein the ratio of the cavity bottom width to the cavity opening width may be 0.05-1. In some examples, the ratio may be 0.1-1.

[0142] When the cavity has a circular shape, the width of the cavity bottom can correspond to the diameter of the cavity at the bottom. When the cavity has a rectangular or square shape, the width of the cavity bottom can correspond to the diagonal of the cavity at the bottom. When the cavity has a circular shape, the width of the cavity opening can correspond to the diameter of the cavity at the entrance. When the cavity has a rectangular or square shape, the width of the cavity opening can correspond to the diagonal of the cavity at the entrance.

[0143] In some examples, each of the pair of cavities in the substrate may have a cavity depth of 0.05 mm to 1.0 mm. In some examples, each of the pair of cavities in the substrate may have a cavity depth of 0.1 mm to 3 mm.

[0144] In some examples, each of the pair of cavities in the substrate may include a cavity bottom width of 0.05 mm to 50 mm. In some examples, the cavity bottom width may be 0.05 mm to 80 mm.

[0145] In some examples, each of a pair of cavities in the substrate may include a cavity opening width of 0.06 mm to 80 mm. In some examples, the cavity opening width may be 0.06 mm to 50 mm.

[0146] In some examples, the ratio of the height of each of a pair of protrusions on the substrate to the depth of each corresponding cavity in a pair of cavities on the substrate can be in the range of 1 to 1.25.

[0147] In some examples, the width of each of a pair of protrusions on the substrate may be equal to the cavity opening width of the corresponding cavity on the upper surface. In other examples, the protrusion width may be greater than the cavity opening width of the corresponding cavity on the upper surface of the substrate.

[0148] In some examples, the cavity opening width of each cavity in a pair of cavities of the substrate may be greater than or equal to the cavity bottom width of each cavity in a pair of cavities of the substrate. In some other examples, the cavity opening width of each cavity in a pair of cavities of the substrate may be less than the cavity bottom width of each cavity in a pair of cavities of the substrate.

[0149] In some examples, the ratio of the cavity bottom width of each cavity in a pair of cavities of the substrate to the cavity opening width of each cavity in a pair of cavities of the substrate may be 0.05-1, and the cavity opening width may be greater than the cavity bottom width.

[0150] In some examples, the cavity width of each cavity in a pair of cavities of the substrate may decrease continuously from the cavity opening width to the cavity bottom width.

[0151] In some examples, each of the pair of cavities in the substrate may have a circular shape, wherein the cavity bottom width (diameter) at the bottom of the cavity is 1.5mm-30mm, the cavity opening width (diameter) at the cavity entrance is 3mm-60mm, the radius at the bottom of the cavity is 0.05mm-5mm, and the radius at the cavity entrance is 0.05mm-5mm.

[0152] In some embodiments, the paired protrusions and / or paired cavities of the upper insulating portion, the substrate, and the lower insulating portion may each have a circular shape.

[0153] In some examples, each of the pair of cavities in the substrate may have a rectangular or square shape, wherein the cavity bottom width (diagonal length) at the bottom of the cavity is 10mm-180mm, and the cavity opening width (diagonal length) at the entrance of the cavity is 10mm-200mm.

[0154] In some examples, each cavity in a pair of cavities of the substrate may include four corners in a cross-sectional view: two entrance corners at the cavity entrance and two bottom corners at the bottom surface of the cavity. The two entrance corners may be rounded or sharp. The two bottom corners may be rounded or sharp. The four corners of each cavity in a pair of cavities of the substrate may include angles of 90° or greater.

[0155] The substrate may additionally include a central hole. The hole may be adapted to be penetrated by rivets or electrodes of the battery cell.

[0156] In some embodiments, the upper insulating portion, the lower insulating portion, and the substrate may each include a central hole.

[0157] The substrate can be rectangular or square. The substrate can have a length of 1cm-200cm, a width of 1cm-60cm, and a diagonal of 1cm-250cm.

[0158] In the context of this invention, the center of a rectangular or square substrate refers to the point or area at the intersection of the diagonals of the rectangular or square substrate. The center may be equidistant from all four edges of the substrate.

[0159] In some examples, the four edges of the substrate may be rounded. In other examples, the four edges of the substrate may be sharp. The rounded or sharp edges of the substrate can perfectly fit into and align with the rounded or sharp edges of the housing. Therefore, a flush-fitting assembly with the housing can be ensured to guarantee a seal.

[0160] In some examples, each of a pair of protrusions on the substrate may be arranged symmetrically about the center of the substrate, and / or each of a pair of cavities on the substrate may be arranged symmetrically about the center of the substrate. This means that each of a pair of protrusions on the substrate and / or each of a pair of cavities on the substrate may be equidistant from the center of the substrate.

[0161] In some examples, for one of two battery cell covers, one of the protrusions of the substrate and / or one of the cavities of the upper insulating portion may be eccentric. Such an arrangement allows for fail-safe assembly of the negative and positive battery covers, since one battery cover may include an eccentric arrangement of protrusions and / or cavities (foolproof design).

[0162] In some examples, for one of the two battery cell covers, one of the protrusions of the substrate and / or one of the cavities of the substrate may have an alternative shape (e.g., rectangular or square) or size. Such an arrangement allows for the failure-protected assembly of the negative and positive battery covers, as one battery cover may include an alternative shape or size arrangement of the protrusions and / or cavities (foolproof design).

[0163] Therefore, in some embodiments, each of the pair of protrusions of the upper insulating portion may be unequally spaced from the center of the upper insulating portion, each of the pair of cavities of the lower insulating portion may be unequally spaced from the center of the lower insulating portion, and / or each of the pair of protrusions and / or each of the pair of cavities of the substrate may be unequally spaced from the center of the substrate.

[0164] The substrate may additionally include a pair of regions, each of which may surround one of a pair of protrusions on the substrate. Thus, each of the pair of protrusions on the substrate may be surrounded by a region. This region may have a higher density than the rest of the bottom surface. Higher density means a density 5% to 50% higher than the density of the bottom surface of the substrate.

[0165] The substrate can be made of materials selected from aluminum, steel, stainless steel, etc.

[0166] The wall thickness of the substrate can range from 0.1 mm to 8 mm. The substrate can include substrates with equal wall thicknesses.

[0167] The substrate may include a wall on the upper surface surrounding the periphery of the substrate, and a groove on the lower surface opposite the wall surrounding the periphery of the substrate. In the context of this invention, "periphery" refers to the entire outer edge of the substrate. The protrusion may have a height of 0.1 mm to 1 mm. The groove depth may be in the range of 0.1 mm to 0.8 mm.

[0168] The substrate of the positive electrode cap may additionally include an injection hole. In the context of this invention, an "injection hole" refers to an opening or port through which electrolyte is introduced into the battery cell after the battery casing and cap, particularly the substrate, are welded together. After the substrate is welded to the casing, the injection hole can be hermetically sealed by a rubber pin and an injection hole sealing pin.

[0169] In some embodiments, the substrate may have a hardness of 20 to 90 HRC as measured according to DIN EN ISO 6508-1. In some examples, the hardness of the substrate may be higher than the hardness of aluminum or aluminum alloys as measured according to DIN EN ISO 6508-1.

[0170] The aforementioned substrate is particularly suitable for materials with high rigidity and hardness, such as stainless steel, which helps to reduce the weight and volume of the battery cover.

[0171] A pair of protrusions on the substrate mate with a pair of cavities in the lower insulating portion, and a pair of cavities on the substrate mate with a pair of protrusions in the upper insulating portion. This means that when the three components of the battery cover are stacked together, the protrusions on the substrate fit into the cavities in the lower insulating portion, and the protrusions in the upper insulating portion fit into the cavities on the substrate. When the substrate, the upper insulating portion, and the lower insulating portion are stacked together, their central holes can be positioned one above the other, and the pair of protrusions in the upper insulating portion, the pair of cavities on the substrate, and the pair of cavities in the lower insulating portion can be equidistantly positioned with respect to the centers of the substrate, the upper insulating portion, and the lower insulating portion.

[0172] Therefore, in some embodiments, each of the pair of protrusions of the upper insulating portion may be equidistant from the center of the upper insulating portion, each of the pair of cavities of the lower insulating portion may be equidistant from the center of the lower insulating portion, and / or each of the pair of protrusions and / or each of the pair of cavities of the substrate may be equidistant from the center of the substrate.

[0173] Additionally, in some embodiments, the battery cover may include a gap in the range of 0.01 mm to 1 mm between a pair of protrusions on the substrate and a pair of cavities in the lower insulating portion. In some other examples, each gap between each protrusion on the substrate and each cavity in the lower insulating portion may be in the range of 0.01 mm to 0.1 mm. The gap may account for component fit tolerances.

[0174] A gap may also be included between a pair of protrusions on the upper insulating portion and a pair of cavities on the substrate in the battery cover. Each gap between each protrusion on the upper insulating portion and each cavity on the substrate may be in the range of 0.01 mm to 1 mm.

[0175] In some embodiments, the battery cover further includes a terminal, a rivet, and a sealing ring with a central hole, wherein the terminal is disposed on the upper insulating portion, the sealing ring is inserted into the holes of the upper insulating portion, the lower insulating portion, and the substrate, and the rivet passes through the sealing ring and is inserted into the holes of the upper insulating portion, the lower insulating portion, and the substrate, wherein the rivet protrudes into the hole of the terminal.

[0176] In the context of this invention, a "terminal" is a conductive component that provides an electrical connection point for a battery cell to an external circuit or device. A terminal facilitates the transfer of current from the battery to the device it powers. The terminal may be located on an upper insulating portion. In particular, the terminal may be fitted in a positively locking manner into an area defined by the wall of the upper insulating portion.

[0177] The battery cell may have two terminals: a positive terminal (cathode) from which current flows out and a negative terminal (anode) from which current flows in. The positive and negative terminals ensure a safe and effective connection to the powered device.

[0178] The positive and negative battery cell covers can be soldered onto the busbar.

[0179] Terminals may include conductive materials selected from the group consisting of stainless steel, copper, or aluminum.

[0180] The terminal includes a hole in the center. The terminal may also be rectangular or square in shape and may have a length of 1cm-100cm, a width of 1cm-50mm, and a diagonal of 1cm-150cm.

[0181] The terminal may include a pair of protrusions on a bottom surface. The bottom surface may be positioned toward the upper insulating portion. The pair of protrusions may mate into a pair of cavities in the upper insulating portion. Each of the protrusions of the terminal may have a height of 0.5 mm to 10 mm and a width of 0.1 mm to 20 mm. Each of the protrusions of the terminal may have the same shape and size as the cavities of the upper insulating portion.

[0182] In the context of this invention, a "sealing ring" refers to a circular component of the cap that is modified to fit precisely between the substrate and the lower plastic insulating portion to prevent electrolyte leakage. The sealing ring can be made of elastic materials such as nitrile rubber, silicone rubber, fluororubber, fluorinated elastomers, EPDM rubber, and neoprene rubber.

[0183] In the context of this invention, "rivet" refers to a mechanical fastener used to securely engage components of a battery cover, thereby maintaining a tight seal to prevent electrolyte leakage. Rivets may be made of materials selected from the group consisting of aluminum, steel, stainless steel, copper, or brass.

[0184] The rivet may be located below the lower insulation portion. The rivet may include an upper surface comprising a pair of cavities. The pair of cavities may mate with a pair of protrusions on the lower insulation portion. Each of the pair of cavities may have a shape selected from circular, semi-circular, rectangular, semi-rectangular, square, semi-square, elliptical, semi-elliptical, triangular, or semi-triangular. Each of the cavities in the rivet may have the same shape and size as the protrusions on the lower insulation portion.

[0185] The aforementioned structural features of the battery cover components allow for flush assembly of different parts. The terminals fit perfectly into the upper insulating portion, a pair of protrusions on the upper insulating portion fit perfectly into the cavity of the substrate, a pair of protrusions on the substrate fit perfectly into the cavity of the lower insulating portion, and the protrusions of the lower insulating portion fit perfectly into the cavity of the rivet. To ensure proper alignment of the aforementioned components of the cover, no additional materials, such as auxiliary components, may be used.

[0186] The precise fit of the cover components, particularly the substrate included within the cover and directly contacting and welded to the casing, can be crucial for the overall safety and / or performance of the battery cell. Specific morphological features of the cover components prevent twisting during impact torques or vibrations, thereby improving the overall safety of the battery cell. Furthermore, due to the specific arrangement of protrusions and cavities in the battery cover components, and the aforementioned differences between the arrangements of protrusions and cavities in the positive and negative electrode covers, the battery cover structure possesses a so-called "foolproof" design, allowing for foolproof manual or automated assembly.

[0187] In some examples, the battery cover may include

[0188] -terminals,

[0189] - Upper insulating part;

[0190] -Substrate;

[0191] -Lower insulation section;

[0192] - Sealing ring; and

[0193] -rivet;

[0194] The terminal, upper insulating portion, substrate, and lower insulating portion may each include holes and may be arranged sequentially from top to bottom. A sealing ring may be inserted into the holes of the upper insulating portion, lower insulating portion, and substrate, and a rivet may pass through the sealing ring and be inserted into the holes of the upper insulating portion, lower insulating portion, and substrate.

[0195] The upper insulating portion may include a pair of circular protrusions on the bottom surface, the lower insulating portion may include a pair of circular cavities on the upper surface and a pair of circular protrusions on the bottom surface opposite to the pair of circular cavities, the substrate may include a pair of circular protrusions on the bottom surface and a pair of circular cavities on the upper surface opposite to the pair of protrusions, and the rivet may include a pair of cavities in a semi-circular shape on the upper surface; and

[0196] A pair of protrusions on the substrate match a pair of cavities in the lower insulating portion, a pair of cavities on the substrate match a pair of protrusions in the upper insulating portion, and a pair of protrusions in the lower insulating portion match a pair of cavities in the rivet.

[0197] A second aspect of the invention relates to a battery cell including the aforementioned battery cover.

[0198] The battery cell can be a rechargeable battery cell. The battery cell can be a lithium-ion battery, nickel-cadmium battery, nickel-metal hydride battery, lithium-sulfur battery, ... or a flow battery.

[0199] The battery cell can be a prismatic battery cell.

[0200] The battery cell may include two caps: a positive cap located at the cathode and a negative cap located at the anode. The positive cap may include an injection hole. The negative cap may include the aforementioned eccentric protrusion and cavity.

[0201] Each battery cell cover may include the aforementioned terminals, an upper insulating portion, a lower insulating portion of the substrate, rivets, and a sealing ring with an anti-torsion structure (matching a pair of protrusions and a pair of cavities in different battery cover components).

[0202] The battery unit can be connected to the busbar.

[0203] As described above, the matching of paired protrusions and paired cavities ensures anti-torsion components within the battery cover, preventing the busbar from tearing from the battery cell and loosening of the battery cover components during impact torques and vibrations. Due to the anti-torsion components of the substrate, weak areas that can be twisted and cracked during battery cell use are avoided, thus improving the overall safety of the battery cell. Furthermore, due to the specific arrangement of the protrusions and cavities along the battery cover components, the battery cover structure has a so-called "foolproof" design, allowing for foolproof manual or automated assembly. The specific arrangement of paired protrusions and paired cavities in the battery cover components further ensures uniform strength and stability around the periphery and center of the battery cover, preventing cracking and minimizing twisting during impact torques. During vibrations and / or impact torques, a pair of protrusions move evenly within the cavity, reducing twisting and mechanical stress distribution throughout the battery cover. In particular, since the substrate can be welded to the battery cell housing, weld breakage is prevented during impact torques due to the anti-torsion structure of the cover.

[0204] Another aspect of the invention relates to a vehicle that includes an energy storage device comprising the aforementioned battery cell.

[0205] The vehicle may be, for example, a trackless and / or chainless land vehicle, particularly a passenger or commercial vehicle.

[0206] An energy storage device may include one or more of the aforementioned battery cells.

[0207] Energy storage devices can be connected to control units, such as battery management systems. The battery management system can monitor the state of the energy storage device, such as its state of charge or health, the charging or discharging process, and can diagnose faults and / or anomalies in the battery cells, such as defective batteries or connection problems.

[0208] In some examples, the control unit may include a computer system and a computer-readable storage medium system, including instructions that, when executed by the computer, enable the computer to analyze and manage the battery.

[0209] Another aspect of the present invention is a method for producing the above-mentioned battery cover, comprising:

[0210] - A metal sheet is stamped to form a substrate, wherein a pair of protrusions are formed on the bottom surface and a pair of cavities are formed on the upper surface, wherein the pair of cavities are opposite to the pair of protrusions;

[0211] - The upper insulating portion is formed by injection molding, wherein a pair of protrusions are formed on the bottom surface;

[0212] - The lower insulating portion is formed by injection molding, wherein a pair of protrusions are formed on the bottom surface and a pair of cavities are formed on the upper surface, wherein the pair of cavities are opposite to the pair of protrusions; and

[0213] - The substrate, the upper insulating portion, and the lower insulating portion are assembled by pressing pairs of protrusions and / or pairs of cavities onto each other, wherein a pair of protrusions of the substrate mates with a pair of cavities of the lower insulating portion and a pair of protrusions of the upper insulating portion mates with a pair of cavities of the substrate.

[0214] In the context of this invention, "stamping" refers to the process of placing a sheet of metal into a stamping press, in which a punch and a die block shape the sheet of metal into a desired shape.

[0215] In some examples, "sheet" may refer to a flexible (continuous) sheet that can be rolled, embossed, and / or stamped to at least some extent.

[0216] The metal sheet can be made of steel, stainless steel, aluminum and / or aluminum alloys.

[0217] For stamping, punches and die blocks can be used.

[0218] In the context of this invention, a "punch" refers to a tool used to apply force to a material (e.g., a substrate) to shape and / or cut the material. A punch may be a hard metal rod with a specific shape at its tip that corresponds to a desired shape or hole to be produced in the substrate.

[0219] The punch can be used to press metal sheets to form the aforementioned substrate, which includes a pair of protrusions and a pair of cavities.

[0220] The height of each of the pair of protrusions can be determined by the material used to fabricate the substrate and / or the wall thickness of the substrate. Materials can be selected from stainless steel, steel, and / or aluminum. Wall thickness can range from 0.5 mm to 20 mm.

[0221] In some examples, a cover with a substrate thickness of 0.5mm-20mm can be used. Therefore, a pair of cavities can be directly stamped into the upper surface of the substrate without deforming the other side of the substrate.

[0222] Substrates with thinner wall thicknesses (0.5mm-10mm) are more advantageous because the overall weight can be lower than that of substrates with thicker wall thicknesses. Lower weight is a general goal in battery design, particularly for applications in electric vehicles.

[0223] In addition, the position and size of the pair of protrusions on the substrate may depend on the size of the aforementioned terminals of the battery cover.

[0224] The punch may have a shape at its tip corresponding to the cavity shape described above on the substrate. The tip of the punch may have the same dimensions as the cavity described above on the substrate.

[0225] In the context of this invention, a "die block" refers to a tool used in conjunction with a punch for shaping or cutting material. A die block typically provides a cavity or anvil on which the punch presses a substrate to produce a desired shape.

[0226] The die block can hold the substrate in the proper position and provide the necessary support and shape to form the substrate when the punch presses on it.

[0227] A stamping substrate can be formed by a stamping process. The stamping substrate includes the pair of protrusions on the bottom surface and the pair of cavities on the upper surface opposite to the pair of protrusions.

[0228] The upper surface of the substrate can be positioned facing the punch. The bottom surface can be located opposite the punch.

[0229] A pair of circular protrusions can be formed on a substrate through a stamping process. Therefore, in a subsequent step, the circular protrusions can be formed, wherein a pair of protrusions including a flat top surface can be formed. During the forming process, the circular top surface can be shaped into a flat top surface forming the protrusions. The flat top surface is important for proper alignment of the substrate with other cover components and / or for ease of manipulation.

[0230] In some examples, during stamping, the aforementioned pair of protrusions on the bottom surface of the substrate and a pair of cavities opposite to the pair of protrusions on the upper surface of the substrate can be formed simultaneously. In the context of this invention, "simultaneously" means at the same time. This means that the aforementioned protrusions and cavities can be formed simultaneously, without overlap or time shift.

[0231] The stamping process ensures the precise formation of the structural features of the substrate, allowing the substrate to be made of materials with high rigidity and hardness, such as stainless steel.

[0232] In the context of this invention, injection molding refers to a manufacturing process for producing parts by injecting molten material, particularly plastic material, into a mold. The injection molding process may include the following steps: melting plastic material, injecting the molten material into a pre-designed mold cavity, allowing the material to cool and solidify, and then ejecting the finished part from the mold. The aforementioned materials used for the upper and lower insulating portions can be used as the plastic material.

[0233] In a further step, the substrate, upper insulating portion, and lower insulating portion are assembled by pressing pairs of protrusions and / or pairs of cavities onto each other, wherein a pair of protrusions on the substrate mates with a pair of cavities on the lower insulating portion, and a pair of protrusions on the upper insulating portion mates with a pair of cavities on the substrate. Through the pressing process, the substrate, upper insulating portion, and lower insulating portion can be connected in a forward-locking manner. In some examples, to account for fit tolerances, the aforementioned gap may exist after the pressing process between the pairs of protrusions and cavities of the substrate, upper insulating portion, and lower insulating portion.

[0234] In some examples, the method further includes the steps of forming the aforementioned terminals, rivets, and sealing pins.

[0235] Terminals and rivets can be formed through an injection molding process.

[0236] In some embodiments, the method further includes the step of connecting the upper insulating portion, the lower insulating portion, and the substrate to the terminal, the rivet, and the sealing ring.

[0237] The above method enables continuous production of battery cell covers.

[0238] In another aspect, the present invention relates to a battery cover that can be obtained by the above method.

[0239] The battery cover obtained by the above method can have the above structural features.

[0240] In another aspect, the present invention relates to the use of a battery cell cover according to the invention for maintaining the mechanical stability of a battery cell.

[0241] This invention can be applied to the automotive industry. Furthermore, it can be used in all fields utilizing batteries and energy storage systems, particularly in areas where large amounts of data are available, such as industry, agriculture, transportation, power supply, and heating. For example, this invention can be used in large-scale industrial power storage systems, small home storage systems, commercial vehicles, laptops, etc.

[0242] In particular, the present invention can be used in fields where lightweight design is required, such as electric aircraft or electric vehicles. Attached Figure Description

[0243] Embodiments of the present invention are described by way of example and with reference to the accompanying drawings, wherein:

[0244] Figure 1 A schematic cross-sectional view of the battery cell cover according to the present invention is shown;

[0245] Figure 2 A schematic cross-sectional view of the substrate according to the present invention is shown;

[0246] Figure 3 A schematic cross-sectional view of the protrusion of the substrate according to the present invention is shown;

[0247] Figure 4 A schematic top view of the substrate according to the present invention is shown;

[0248] Figure 5 The assembly of the battery cover component according to the present invention is illustrated schematically;

[0249] Figure 6 The gap between the protrusion of the upper insulating portion and the cavity of the substrate is schematically shown according to the present invention;

[0250] Figure 7 A battery cell according to the present invention is shown schematically;

[0251] Figure 8 A vehicle according to the present invention is shown schematically;

[0252] Figure 9 The method according to the invention is illustrated schematically;

[0253] Figure 10a A schematic cross-sectional view of the substrate is shown; and

[0254] Figure 10b A schematic cross-sectional view of the substrate is shown. Detailed Implementation

[0255] Figure 1 A cross-sectional view of the battery cover 1 according to the present invention is shown.

[0256] The battery cover 1 includes a terminal 5, an upper insulating portion 2, a substrate 4, a lower insulating portion 3, a sealing ring 7, and a rivet 6. The terminal 5, the upper insulating portion 2, the substrate 4, and the lower insulating portion 3 each include holes (5f, 2f, 4f, 3f, not shown) at the center (5e, 2e, 4e, 3e) and are arranged sequentially from top to bottom. The sealing ring 7 is inserted into the holes (5f, 2f, 4f, 3f) of the upper insulating portion 2, the lower insulating portion 3, and the substrate 4, and the rivet 6 passes through the sealing ring 7 and is inserted into the holes (5f, 2f, 4f, 3f) of the upper insulating portion 2, the lower insulating portion 3, and the substrate 4.

[0257] The upper insulating portion 2 includes a pair of circular protrusions 2a on the bottom surface 2b, the lower insulating portion 3 includes a pair of circular cavities 3c on the upper surface 3d and a pair of circular protrusions 3a on the bottom surface 3b opposite to the pair of circular cavities 3c, the substrate 4 includes a pair of circular protrusions 4a on the bottom surface 4b and a pair of circular cavities 4c on the upper surface 4d opposite to the pair of protrusions 4a, and the rivet 6 includes a pair of cavities 6c in a semi-circular shape on the upper surface 6d.

[0258] A pair of protrusions 4a on the substrate 4 match a pair of cavities 3c on the lower insulating portion 3, a pair of cavities 4c on the substrate 4 match a pair of protrusions 2a on the upper insulating portion 2, and a pair of protrusions 3a on the lower insulating portion 3 match a pair of cavities 6c on the rivet 6.

[0259] The terminal includes a hole 5e at its center 5f. The terminal fits perfectly between the walls 12 of the upper insulating portion 2.

[0260] Due to the specific structure of the battery cover assembly, proper alignment of the substrate, upper and lower insulation portions, terminals, and rivets is possible. This specific structure ensures anti-torsion characteristics, which maximizes battery cell life and overall safety when the battery cell is exposed to impact torques and / or vibrations. Additionally, the specific structure of the battery cover assembly incorporates a foolproof design.

[0261] Figure 2 A schematic cross-sectional view of the substrate 4 according to the present invention is shown.

[0262] The substrate 4 includes a pair of protrusions 4a on the bottom surface 4b and a pair of cavities 4c on the upper surface 4d. The pair of protrusions 4a and the pair of cavities 4c face away from each other. The pair of protrusions 4a and the pair of cavities 4c are equidistant from the center 4e of the substrate.

[0263] Figure 3 A schematic cross-sectional view of the protrusion 4aa and cavity 4ca of the substrate 4 according to the present invention is shown.

[0264] One of the pair of protrusions 4aa of the substrate 4 is positioned opposite to one of the pair of cavities 4ca. The protrusion 4aa includes a top surface 8, a protrusion width w1, and a protrusion height t1. The ratio of the protrusion height t1 to the protrusion width w1 of a single protrusion is between 0.5 and 50.1. The protrusion height t1 is the distance between the top surface 8 of the protrusion and the bottom surface 4b of the substrate 4. The protrusion 4 includes a larger width adjacent to the bottom surface 4b and a smaller width at the top surface 8.

[0265] When viewed in a cross-sectional view, the protrusion 4aa further includes two corners cb1 and cb2 at the top surface 8. The two corners cb1 and cb2 are rounded and have an angle greater than 90°.

[0266] The upper surface 4d of the substrate 4 includes a pair of cavities 4c opposite to a pair of protrusions 4a on the bottom surface 4b of the substrate 4. Each cavity 4ca of the pair of cavities 4c of the substrate 4 includes a cavity depth d, a cavity bottom width wg1, and a cavity opening width wo1. The depth d of each cavity 4ca is in the range of 0.05 mm to 1.0 mm. The cavity opening width wo1 is greater than the cavity bottom width wg1. In addition, in the cross-sectional view, the cavity 4ac includes four corners cc1-cc4, namely two entrance corners cc1 and cc2 located at the cavity entrance and two bottom corners cc3 and cc4 located at the bottom surface 14 of the cavity 4ca.

[0267] The protrusion 4aa is surrounded by a region a with high density.

[0268] Figure 4 A schematic top view of the upper surface 4d of the substrate according to the present invention is shown.

[0269] The substrate 4 has a rectangular shape with a length l, a width w, and a diagonal db. The substrate includes an upper surface 4d, which includes a hole 4f as a through hole at a center 4e and a pair of cavities 4c equidistant from the center 4e and the hole 4f of the substrate 4. The substrate also includes a sealed injection hole 13.

[0270] Figure 5 The assembly of the battery cover 1 component according to the present invention is illustrated schematically.

[0271] The battery cover 1 includes terminals 5, an upper insulating portion 2, a substrate 4, a sealing ring 7, a lower insulating portion 3, and rivets 6 arranged from a top view to a bottom view. The sealing ring 7 is inserted into holes (5f, 2f, 4f, 3f) in the upper insulating portion 2, the lower insulating portion 3, and the substrate 4, and the rivets 6 pass through the sealing ring 7 and are inserted into holes (5f, 2f, 4f, 3f) in the upper insulating portion 2, the lower insulating portion 3, and the substrate 4.

[0272] The upper insulating portion 2 includes a wall 12 surrounding its entire periphery and a pair of protrusions 2a (not shown) on the bottom surface 2b. The substrate includes a pair of cavities 4c equidistant from the central hole 4f on the upper surface 4d, a sealed injection hole 13, and a pair of protrusions 4a opposite to the pair of cavities 4c on the bottom surface 4b (not shown). The lower insulating portion 3 includes a pair of cavities 3c on the upper surface 3c, a pair of protrusions 3a (not shown) on the bottom surface 3b, and three segments 3g at each short side.

[0273] The rivet 6 includes a pair of semi-circular cavities 6c on the upper surface 6d.

[0274] A pair of protrusions 4a on the substrate 4 match a pair of cavities 3c on the lower insulating portion 3, a pair of cavities 4c on the substrate 4 match a pair of protrusions 2a on the upper insulating portion 2, and a pair of protrusions 3a on the lower insulating portion 3 match a pair of cavities 6c on the rivet 6.

[0275] Figure 6 The gap 8 between the protrusion 2aa of the upper insulating portion 2 and the cavity 4ca of the substrate 4 is schematically shown according to the present invention.

[0276] The battery cover 1 includes a gap 8 in the range of 0.01 mm to 1 mm between a pair of cavities 4c (one cavity 4ca is shown in the pair) on the substrate 4 and a pair of protrusions 2aa (one cavity 2ca is shown in the pair) on the upper insulating portion 2. The gap 8 takes into account the fitting tolerances of the components. A gap is also included in the battery cover 1 between a pair of protrusions 4a on the substrate 4 and a pair of cavities 3c on the lower insulating portion 3.

[0277] Figure 7 The structure of a battery cell 9 according to the present invention is schematically shown. The battery cell 9 includes, as follows: Figure 1 and 5 The aforementioned battery cover.

[0278] Figure 8 The structure of a vehicle 10 according to the present invention is schematically shown. The vehicle 10 includes... Figure 7 The energy storage device 11 of the battery unit 9.

[0279] Figure 9 The method 100 according to the present invention is illustrated schematically. The method includes the following steps:

[0280] Step 101: Stamp a metal sheet to form a substrate 4, wherein a pair of protrusions 4a are formed on the bottom surface 4b and a pair of cavities 4c are formed on the upper surface 4d, wherein the pair of cavities 4c are opposite to the pair of protrusions 4a.

[0281] A pair of circular protrusions are formed on the substrate 4 through a stamping process. Therefore, after stamping, the circular protrusions must be formed, wherein a pair of protrusions 4a including a flat top surface 4g are formed. During the forming process, the circular top surface can be formed into the flat top surface 4g that forms the protrusion 4.

[0282] Step 102: The upper insulating portion 2 is formed by injection molding, wherein a pair of protrusions 2a are formed on the bottom surface 2b.

[0283] Step 103: The lower insulating portion 3 is formed by injection molding, wherein a pair of protrusions 3a are formed on the bottom surface 3b and a pair of cavities 3c are formed on the upper surface 3d, wherein the pair of cavities 3c are opposite to the pair of protrusions 3a.

[0284] Step 104: Assemble the substrate 4, the upper insulating portion 2, and the lower insulating portion 3 by pressing pairs of protrusions (2a, 3a, 4a) and / or pairs of cavities (2c, 3c, 4c) onto each other, wherein a pair of protrusions (4) of the substrate 4 matches a pair of cavities (3c) of the lower insulating portion 3 and a pair of protrusions (2a) of the upper insulating portion 2 matches a pair of cavities (4c) of the substrate 4.

[0285] Step 105: Connect the upper insulating part 2, the lower insulating part 3 and the substrate 4 using the terminal 5, rivet 6 and sealing ring 7.

[0286] Figure 10a A substrate 4 of a battery cell cover 1 excluding a pair of cavities 4c is schematically shown. In such a battery cell cover, the lower insulating portion 3 includes a pair of cavities 3c on the upper surface 3d, and the substrate 4 includes a pair of protrusions 4a on the bottom surface 4b, and the pair of protrusions 4a of the substrate 4 mate with the pair of cavities 3c of the lower insulating portion 3.

[0287] Figure 10b The substrate 4 of the battery cell cover 1 is schematically shown, which includes a pair of cavities 4c and a pair of protrusions 4a opposite to the pair of cavities 4c. In this type of battery cell cover 1, the upper insulating portion 2 includes a pair of protrusions 2a on the bottom surface 2b, the lower insulating portion 3 includes a pair of cavities 3c on the upper surface 3d, and the substrate 4 includes a pair of protrusions 4a on the bottom surface 4b and a pair of cavities 4c on the upper surface 4d opposite to the pair of protrusions 4a. The pair of protrusions 4a of the substrate 4 matches the pair of cavities 3c of the lower insulating portion 3, and the pair of protrusions 2a of the upper insulating portion 2 matches the pair of cavities 4c of the substrate 4.

[0288] List of reference numerals

[0289] 1 Battery cell cover

[0290] 2. Upper insulation part

[0291] A pair of protrusions on the upper insulating portion of 2a

[0292] Each of the two protrusions in the insulating portion of 2aa / 2ab

[0293] 2b Bottom surface of the upper insulating part

[0294] A pair of cavities in the insulating portion of 2c

[0295] The upper surface of the 3D insulating part

[0296] 2e Center of the upper insulating part

[0297] Holes in the insulating portion of 2f

[0298] 3. Lower insulation section

[0299] 3a A pair of protrusions in the lower insulating portion

[0300] 3b Bottom surface of the lower insulating part

[0301] A pair of cavities in the lower insulating part of 3c

[0302] Each of the two cavities in the 3ca / 3cb lower insulation section

[0303] 3d Lower insulation part upper surface

[0304] 3e Center of the lower insulation part

[0305] 3f Holes in the lower insulating section

[0306] 3g lower insulation section

[0307] 4 substrate

[0308] A pair of protrusions on the 4a substrate

[0309] Each of the two bumps on the 4aa / 4ab substrate

[0310] 4b Bottom surface of the substrate

[0311] A pair of cavities on a 4c substrate

[0312] Each cavity in a pair of cavities of a 4ca / 4cb substrate

[0313] Top surface of 4D substrate

[0314] 4e The center of the substrate

[0315] 4f substrate holes

[0316] Top surface of 4g substrate

[0317] 5 terminals

[0318] 5e terminal center

[0319] 5f terminal hole

[0320] 6 Rivets

[0321] 6c A pair of cavities in a rivet

[0322] The upper surface of a 6D rivet

[0323] 7. Sealing ring

[0324] 9 battery cells

[0325] 10 vehicles

[0326] 11 Energy storage devices

[0327] 12. The wall of the upper insulating part

[0328] 13 Sealed injection port

[0329] 14. Bottom surface of cavity

[0330] 100 Methods for producing battery covers

[0331] 101 Stamped Metal Sheet

[0332] 102 Forming the upper insulating part

[0333] 103 Forms the lower insulation portion

[0334] 104 Assembled substrate

[0335] 105 Connections

[0336] t1 is the protrusion height of the substrate.

[0337] w1 is the protrusion width of the substrate.

[0338] wg1 substrate cavity bottom width

[0339] wo1 Cavity opening width of the substrate

[0340] d Depth of the cavity in the substrate

[0341] The angle at the entrance of cc1 / cc2 cavity

[0342] The angle at the bottom surface of the cc3 / cc4 cavity

[0343] l Length of substrate

[0344] w is the width of the substrate.

[0345] The diagonal of the db substrate

[0346] a high-density area

[0347] wt is the wall thickness of the substrate.

Claims

1. A battery cover (1), comprising: - Upper insulating part (2); - Lower insulation part (3); as well as - A substrate (4) is disposed between the upper insulating portion (2) and the lower insulating portion (4); The lower insulating portion (3) includes a pair of cavities (3c) on the upper surface (3d), and the substrate (4) includes a pair of protrusions (4a) on the bottom surface (4b), and the pair of protrusions (4a) of the substrate (4) matches the pair of cavities (3c) of the lower insulating portion (3).

2. The battery cover (1) according to claim 1, Furthermore, the upper insulating portion (2) includes a pair of protrusions (2a) on the bottom surface (2b), the lower insulating portion (3) includes a pair of cavities (3c) on the upper surface (3d), and the substrate (4) includes a pair of protrusions (4a) on the bottom surface (4b) and a pair of cavities (4c) on the upper surface (4d) opposite to the pair of protrusions (4a), wherein the pair of protrusions (4a) of the substrate (4) matches the pair of cavities (3c) of the lower insulating portion (3) and the pair of protrusions (2a) of the upper insulating portion (2) matches the pair of cavities (4c) of the substrate (4).

3. The battery cover (1) according to claim 1 or claim 2, wherein - Each of the pair of protrusions (2a) of the upper insulating portion (2) (2aa, 2ab) is equidistant from the center (2e) of the upper insulating portion (2). - Each cavity (3ca, 3cb) of the pair of cavities (3c) of the lower insulating portion (3) is equidistant from the center (3e) of the lower insulating portion (3), and / or - Each of the pair of protrusions (4aa, 4ab) and / or each of the pair of cavities (4c, 4ca, 4cb) of the substrate (4) is equidistant from the center (4e) of the substrate (4).

4. The battery cover (1) according to claim 1 or claim 2, wherein - Each of the pair of protrusions (2a) of the upper insulating portion (2) (2aa, 2ab) is not equidistant from the center (2e) of the upper insulating portion (2). - Each cavity (3ca, 3cb) of the pair of cavities (3c) of the lower insulating portion (3) is not equidistant from the center (3e) of the lower insulating portion (3), and / or - Each of the pair of protrusions (4aa, 4ab) and / or each of the pair of cavities (4c, 4ca, 4cb) of the substrate (4) is not equidistant from the center (4e) of the substrate (4).

5. The battery cover (1) according to any one of the preceding claims further includes a terminal (5), a rivet (6) and a sealing ring (7), the terminal (5) including a hole (5f) at a center (5e), ​​wherein the terminal (5) is disposed on the upper insulating portion (2), the sealing ring (7) is inserted into holes in the upper insulating portion (2), the lower insulating portion (3) and the substrate (4), and the rivet (6) passes through the sealing ring (7) and is inserted into holes (2f, 3f, 4f) in the upper insulating portion (2), the lower insulating portion (3) and the substrate (4), wherein the rivet (6) protrudes into the hole (5f) of the terminal (5).

6. The battery cover (1) according to any one of the preceding claims includes a gap (8) between the pair of protrusions (4a) on the substrate (4) and the pair of cavities (3c) of the lower insulating portion (3), the gap (8) being in the range of 0.01 mm to 1 mm.

7. The battery cover (1) according to any one of the preceding claims, wherein the pair of protrusions (2a, 3a, 4a) and / or the pair of cavities (2c, 3c, 4c) of the upper insulating portion (2), the substrate (4) and the lower insulating portion (3) each have a circular shape.

8. The battery cover (1) according to any one of the preceding claims, wherein each of the pair of protrusions (4a) of the substrate (4) includes a protrusion width (w1) and a protrusion height (t1), wherein the ratio of the protrusion height (t1) to the protrusion width (w1) is 0.5 to 51.

9. The battery cover (1) according to any one of the preceding claims, wherein each of the pair of cavities (4c) of the substrate (4) includes a cavity bottom width (wg1) and a cavity opening width (wo1), wherein the ratio of the cavity bottom width (wg1) to the cavity opening width (wo1) is 0.05 to 1.

10. A battery cell (9) comprising a battery cover (1) according to any one of claims 1 to 9.

11. A vehicle (10) comprising an energy storage device (11) including a battery cell (9) according to claim 10.

12. A method (100) for producing a battery cover (1) according to any one of claims 1 to 9, comprising: -(101) Stamping a metal sheet to form a substrate (4), wherein a pair of protrusions (4a) on the bottom surface (4b) and a pair of cavities (4c) on the upper surface (4d) are formed, wherein the pair of cavities (4c) are opposite to the pair of protrusions (4a); -(102) The upper insulating portion (2) is formed by injection molding, wherein a pair of protrusions (2a) are formed on the bottom surface (2b); -(103) The lower insulating portion (3) is formed by injection molding, wherein a pair of protrusions (3a) on the bottom surface (3b) and a pair of cavities (3c) on the upper surface (3d) are formed, wherein the pair of cavities (3c) are opposite to the pair of protrusions (3a); as well as -(104) The substrate (4), the upper insulating portion (2) and the lower insulating portion (3) are assembled by pressing the pair of protrusions (2a, 3a, 4a) and / or the pair of cavities (2c, 3c, 4c) onto each other, wherein the pair of protrusions (4a) of the substrate (4) matches the pair of cavities (3c) of the lower insulating portion (3), and the pair of protrusions (2a) of the upper insulating portion (2) matches the pair of cavities (4c) of the substrate (4).

13. The method according to claim 12, further comprising the step (105) of connecting the upper insulating portion (2), the lower insulating portion (3) and the substrate (4) using a terminal (5), a rivet (6) and a sealing ring (7).

14. A battery cover (1) that can be obtained by the method according to any one of claims 12 to 13.

15. The use of the battery cover (1) according to any one of claims 1 to 9 or 14 for maintaining the mechanical stability of the battery cell (9).

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