Power Battery Top Cover Plate Injection-Molded Insulator
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Solution Overview
Problem
The existing power battery top cover plate structure is time-consuming and costly to install, with a high risk of poor welding and safety concerns due to the multiple processes involved in installing power battery poles using aluminum rings and friction welding, which can lead to the welding falling off.
Innovation Solution
A power battery top cover plate structure featuring a top cover sheet with pole holes, upper and lower insulators, and power battery poles with protrusions and recesses for secure positioning, along with an explosion-proof valve, reduces installation processes and costs by using injection-molded plastic for fixed installation and enhancing safety through a blasting score for pressure release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum rings and friction welding are used to install power battery poles on top cover sheets, then the poles can be securely installed, but the installation process becomes time-consuming and complex with multiple steps involved
Solution Approach 1:
The patent combines the aluminum ring, insulator, and pole installation into a single integrated structure. The aluminum ring is formed as one piece with the insulator, eliminating the need for separate components and assembly steps. This merging reduces installation complexity while maintaining secure pole attachment through the integrated aluminum ring structure.
Solution Approach 2:
The patent segments the pole installation system into distinct functional zones: the aluminum ring for mechanical attachment, the insulator for electrical isolation, and the pole body for current conduction. This segmentation allows each component to be optimized for its specific function while simplifying the overall installation process through standardized interfaces.
2Reliability
If aluminum rings and friction welding are used to install power battery poles, then secure installation is achieved, but production cost increases due to multiple installation processes
Solution Approach 1:
The aluminum ring and insulator are merged into a single integrated component that can be manufactured in one molding process. This eliminates the need for separate manufacturing and assembly operations, reducing production costs while maintaining the secure installation function of the aluminum ring.
Solution Approach 2:
The patent replaces the friction welding process with a mechanical insertion method. The pole is simply inserted into the aluminum ring without requiring welding operations, eliminating the complexity and cost of welding equipment and processes while maintaining secure mechanical attachment.
3Ease of manufacture
If friction welding is used to join copper plate and aluminum plate for negative pole formation, then the pole can be assembled, but the welding is easy to fall off and safety system is low
Solution Approach 1:
The patent replaces friction welding with a pure mechanical insertion system. The copper plate and aluminum plate are joined through the aluminum ring structure using mechanical interference fits and locking features, eliminating the unreliable welding process while maintaining easy assembly through simple insertion motions.
Solution Approach 2:
The patent employs curved and tapered surfaces in the aluminum ring and pole interface to create self-centering and self-locking effects. The curved geometry provides mechanical interference that prevents the pole from falling out, replacing the need for welding while ensuring durable connection.
4Reliability
If multiple installation processes are used for power battery poles, then secure attachment can be achieved, but installation time increases making the process more time-consuming
Solution Approach 1:
The patent merges multiple installation operations into a single pole insertion motion. The aluminum ring, insulator, and securing features are integrated so that one insertion action simultaneously achieves electrical connection, mechanical attachment, and insulation, dramatically increasing installation speed while maintaining security.
Solution Approach 2:
The aluminum ring and insulator are pre-assembled into an integrated unit before installation. This preliminary preparation allows the pole to be installed in a single operation without requiring sequential steps for attaching different components, improving installation productivity while ensuring secure attachment.
Data Source
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AI summary
A power battery top cover plate structure is disclosed in the present invention. A first protrusion protruding obliquely outwards is arranged on a battery pole, the battery pole and a connecting body of a lower insulator are placed in a pole hole of a top cover sheet, and then an annular area formed by a combination of an annular first protrusion on the battery pole and a locking block on the pole hole is wrapped by plastic to form an upper insulator, thus completing fixed installation of the battery pole and the lower insulator. The arrangement reduces installation accessories, reduces production costs by more than %, and at the same time improves the production efficiency, so that the yield and product quality are greatly improved.