Battery Cap Groove Structure for Higher Cell Capacity
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Solution Overview
Problem
The volume of cells that can be accommodated in batteries is relatively small, leading to decreased battery capacity and electrical energy provision.
Innovation Solution
A battery cap design featuring a cap plate with a first groove and a lower insulating member with a protrusion, along with an electrode lead-out member, which reduces the occupation of internal space by the insulating member and electrode components, allowing for increased cell height and capacity without changing the battery casing volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery cap uses a conventional design without grooves or protrusions, then the structure is simple and easy to manufacture, but the internal space of the battery casing is not fully utilized, resulting in smaller cell volume and reduced battery capacity
Solution Approach 1:
The battery cap structure is segmented into multiple functional components: the cap plate with first groove for accommodating the lower insulating member, and the second groove for accommodating the connecting plate. This segmentation allows each component to be optimized independently while collectively maximizing space utilization within the battery casing.
Solution Approach 2:
The design employs a nested arrangement where the lower insulating member with its protrusion is nested within the first groove of the cap plate, and the connecting plate is nested within the second groove. This nesting approach allows multiple components to occupy overlapping or adjacent spaces efficiently, maximizing the use of available internal volume without increasing the external dimensions of the battery cap.
2Reliability
If the lower insulating member occupies more space in the battery casing, then the insulating performance is improved, but the available space for the cell is reduced, leading to smaller cell volume and lower battery capacity
Solution Approach 1:
The design transitions from a two-dimensional planar arrangement to a three-dimensional spatial configuration by creating grooves that extend into the cap plate thickness. The lower insulating member is positioned within the first groove, utilizing the vertical dimension of the cap plate structure. This dimensional approach allows the insulating member to provide adequate insulation while occupying space that would otherwise be unused, rather than expanding horizontally into the cell volume.
3Reliability
If the electrode lead-out member uses a larger connecting plate for better electrical connection, then the electrical conductivity is improved, but the space occupied in the battery casing increases, reducing the cell volume that can be accommodated
Solution Approach 1:
The electrode lead-out member is segmented into the connecting plate and the electrode terminal as distinct components with separate functions. The connecting plate is specifically designed to fit within the second groove, providing a localized area for electrical connection without requiring a large overall footprint. This segmentation allows the electrical connection function to be optimized independently from the space occupation of the entire lead-out member.
Data Source
Figure 1~2
Figure 3~4
AI summary
A battery cap and a battery are provided. At least a region of a first surface (110) of a cap plate (100) is provided with a first groove (130). At least a region of a third surface (210) of a lower insulating member (200) is provided with a first protrusion (230). The first protrusion is accommodated in the first groove. The portion of a fourth surface (220) corresponding to the first protrusion is provided with a second groove (240). In a first direction (X), a bottom portion of the second groove is higher than a lowest position of the cap plate. One end of the electrode terminal (320) facing away from a connecting plate (310) passes through the lower insulating member and the cap plate and extends to a second surface (120). The connecting plate arranged in the second groove abuts against a bottom wall of the second groove.