Secondary Battery Cap Cover Protrusion Design
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Solution Overview
Problem
Existing secondary batteries lack effective protection for connection members from damage during assembly and operation, particularly due to sharp edges or burrs from components like temperature-sensing elements and lead terminals.
Innovation Solution
The secondary battery design incorporates protrusions on the cap cover to support connection members above the cap cover, creating a gap that prevents physical damage and includes an assembling rib to guide the battery cell's proper positioning, ensuring the connection members are protected from sharp edges and burrs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection members are placed directly on the cap cover, then assembly is simple, but the connection members are vulnerable to damage from sharp edges and welding burrs
Solution Approach 1:
The patent introduces protrusions on the cap cover as intermediary protective elements between the connection members and the cap cover body. These protrusions create a gap that prevents direct contact between the connection members and potential damage sources like sharp edges and welding burrs on the cap cover, thereby protecting the connection members without requiring a completely separate protective component.
Solution Approach 2:
The protrusions are pre-formed on the cap cover during manufacturing, creating protective gaps before the connection members are installed. This preliminary structural preparation ensures that the connection members are automatically protected from damage upon assembly, eliminating the need for additional protective measures during the assembly process.
2Reliability
If protrusions are added to the cap cover to protect connection members, then connection members are protected from damage, but the cap cover structure becomes more complex
Solution Approach 1:
The protective protrusions are integrated directly into the cap cover structure, merging the protective function with the existing cap cover component. This eliminates the need for separate protective parts and reduces the overall number of manufacturing steps, as the protrusions can be formed during the standard cap cover molding process.
Solution Approach 2:
The protrusions serve multiple functions: they provide mechanical protection for connection members from sharp edges and welding burrs, create necessary gaps for proper positioning, and can also serve as alignment features during assembly. This multi-functionality reduces the need for additional specialized components.
3Object-affected harmful factors
If connection members are supported above the cap cover, then protection from sharp edges is improved, but assembly precision requirements increase
Solution Approach 1:
The protrusions are designed to automatically guide and position the connection members during assembly through their geometric configuration. The connection members self-align with the protrusions without requiring external positioning tools or complex alignment procedures, thereby reducing assembly precision requirements while maintaining protective spacing.
Solution Approach 2:
The protrusions create localized protective zones at specific critical areas where connection members are most vulnerable to sharp edges and welding burrs. Rather than requiring uniform precision across the entire assembly area, the protection is concentrated at the local interfaces between the cap cover and connection members.
Data Source
AI summary
A secondary battery is disclosed. In one aspect, a secondary battery includes a battery cell including an electrode, a cap cover placed over the battery cell and having an opening that exposes the electrode and a connection member placed over the cap cover and electrically connected to the electrode. The secondary battery also includes a protrusion extending upwardly from the cap cover and contacting the connection member, wherein a gap is formed between the cap cover and the connection member.