Battery Cap Protrusions for Low Resistance Vibration
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Solution Overview
Problem
Advances in battery development have increased complexity, leading to reliability issues and battery failure due to increased contact resistance and potential electrical disconnection, especially in high-vibration applications.
Innovation Solution
A battery cap assembly with an upper cap part featuring protrusions on its lower surface that engage a safety apparatus, ensuring a secure and low-resistance electrical connection by embedding the protrusions into the safety apparatus when the battery housing is deformed, using materials like plated steel or stainless steel for the protrusions and aluminum for the safety apparatus, and welding them together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components are included in the battery to enhance safety and functionality, then the battery's safety and features are improved, but the device complexity increases leading to reliability issues and potential failure
Solution Approach 1:
The patent combines the cap assembly and safety apparatus into a single integrated unit. The safety apparatus is positioned between the upper cap part and the electrode assembly, with protrusions from the upper cap part directly engaging with the safety apparatus. This merging eliminates the need for separate retention mechanisms while ensuring both structural integrity and safety functionality.
2Reliability
If the upper cap part is firmly connected to the safety apparatus, then contact resistance is reduced, but the manufacturing precision requirements increase due to the need for precise protrusion engagement
Solution Approach 1:
The protrusions are pre-formed on the lower surface of the upper cap part during the molding process. These protrusions are positioned to automatically engage with corresponding features on the safety apparatus when the cap assembly is assembled, eliminating the need for post-assembly alignment adjustments and ensuring consistent electrical contact.
Solution Approach 2:
The patent specifies that the protrusions have a hardness greater than the hardness of the facing surface of the safety apparatus. This parameter change in material hardness ensures that the protrusions can firmly engage with and maintain electrical contact with the safety apparatus, reducing contact resistance while accommodating reasonable variations in manufacturing tolerances.
3Reliability
If the protrusions are made harder than the safety apparatus surface to ensure firm engagement, then the electrical connection is improved, but the difficulty of manufacture increases due to material selection and processing requirements
Solution Approach 1:
The upper cap part is formed from a composite material or a material with graded properties that provides both the necessary mechanical strength and electrical conductivity. The protrusions are integrated into this material structure, combining the benefits of hardness for firm engagement with the electrical properties needed for low contact resistance, while maintaining manufacturability through established molding and processing techniques.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively maintains low contact resistance and enhances the battery's ability to withstand vibration and internal pressure, preventing significant increases in internal resistance and extending the battery's lifespan in high-vibration environments.
Implementation Method 1
when the edge of the battery housing is deformed to retain the battery cap assembly in the battery housing
Implementation Method 2
welding them together
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3A~4A
AI summary
A battery cap assembly, including a first cap part and a safety apparatus provided under the first cap part, wherein the first cap part includes protrusions on a lower surface thereof, the protrusions configured to engage the safety apparatus.