Battery Cap Assembly With Isolated Busbar Plate Support
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Solution Overview
Problem
The cap assembly in existing battery technologies has a complex structure and poor stability, which affects the service life of batteries by allowing direct contact between the busbar plate and the housing, leading to pressure resistance issues.
Innovation Solution
A cap assembly design featuring a plastic pad with an isolation portion that covers the busbar plate, preventing contact with the housing, and includes a receiving groove to secure the busbar plate, enhancing structural stability and pressure resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cap assembly uses a simple structure without isolation portion, then the device complexity is reduced, but the busbar plate contacts the housing directly causing poor stability and reduced service life
Solution Approach 1:
The plastic pad with isolation portion serves as an intermediary component between the busbar plate and the housing. This mediator prevents direct contact between the conductive busbar plate and the housing, eliminating the harmful effect while maintaining a relatively simple overall structure. The isolation portion specifically addresses the stability issue without requiring complete structural redesign.
2Reliability
If the cap assembly includes isolation portion to prevent contact, then the stability is improved, but the device complexity increases
Solution Approach 1:
The isolation portion is merged with the plastic pad to form an integrated component. Instead of adding a separate isolation element, the design combines the isolation function into the existing plastic pad structure, thereby improving stability while minimizing the increase in device complexity. The receiving groove is also integrated into the plastic pad, further consolidating multiple functions into a single component.
Solution Approach 2:
The plastic pad is designed to perform multiple functions simultaneously: it provides electrical isolation through the isolation portion, mechanical support through the receiving groove, and structural connection between components. This multi-functionality reduces the need for additional separate components, balancing improved reliability with controlled complexity.
3Device complexity
If the busbar plate is directly connected to housing, then the assembly is simpler, but the pressure resistance of the battery deteriorates
Solution Approach 1:
The plastic pad with isolation portion acts as a mediator that prevents direct contact between the busbar plate and housing. This intermediary structure distributes mechanical loads more effectively, improving the battery's pressure resistance without requiring a completely different assembly approach. The receiving groove specifically accommodates the busbar plate to enhance structural support.
Data Source
AI summary
The present disclosure provides a cap assembly, a battery, a battery module, a battery pack, and a vehicle. The cap assembly is used for the battery. The battery includes a cell and a housing for accommodating the cell. The cap assembly includes a busbar plate and a plastic pad. The busbar plate is arranged in the housing, and is attached to the top end of the cell so as to be connected to the cell. The plastic pad is located between the housing and the busbar plate. An edge of the plastic pad extends in a direction close to the busbar plate to form an isolation portion. The plastic pad can cover the busbar plate through the isolation portion, and one side of the isolation portion can be attached to an inner wall of the housing.