Battery Cover Insulating Flap for Assembly Complexity Reduction
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Solution Overview
Problem
The complexity and cost of battery assembly are increased by the use of multiple insulators in batteries, which complicates the connection of electrodes to terminals.
Innovation Solution
A cover assembly with an electrically insulating flap that integrates the functions of multiple insulators, providing electrical communication between electrodes and terminals while reducing the number of parts and complexity by positioning the flap between connectors and electrodes, thereby simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulators are used to prevent unwanted contact between tabs, electrodes, and covers, then electrical insulation reliability is improved, but device complexity and assembly cost increase
Solution Approach 1:
The patent combines multiple separate insulators (first insulator between tab and electrode, second insulator between tab and cover, and connector insulation) into a single integrated insulating flap. This flap is positioned between the connector and the electrode/cover assembly, providing all necessary insulation functions simultaneously. The merging reduces the number of parts from three or more separate insulating components to one unified insulating structure, thereby reducing assembly complexity while maintaining electrical insulation reliability.
2Reliability
If multiple insulators and insulated tabs are used, then electrical insulation reliability is improved, but the number of parts and manufacturing cost increase
Solution Approach 1:
The patent integrates multiple insulating functions into a single insulating flap component. Instead of using separate first insulators, second insulators, and connector insulation layers, the design employs one multifunctional flap that provides all necessary electrical insulation. This reduces the quantity of insulating parts from three or more separate components to a single integrated piece, thereby reducing manufacturing cost and simplifying inventory management while maintaining the same level of electrical insulation reliability.
3Reliability
If multiple insulators are used to prevent unwanted contact, then electrical insulation reliability is improved, but assembly time and productivity are reduced
Solution Approach 1:
The patent consolidates multiple insulation components into a single insulating flap that can be installed in one assembly operation. Instead of separately installing a first insulator, a second insulator, and connector insulation, the unified flap design allows all insulation functions to be achieved simultaneously during a single assembly step. This reduces assembly time and improves manufacturing productivity while maintaining the required electrical insulation reliability between tabs, electrodes, and covers.
Data Source
AI summary
The battery includes a cover assembly on a battery case. The cover assembly includes a battery cover coupled with an electrically insulating flap of material. The battery can include a first electrical connector that provides electrical communication between a terminal in the cover and one or more first electrodes in the battery. The first connector is at least partially positioned between a first region of the flap and a second region of the flap. The battery can also includes a second electrical connector that provides electrical communication between the cover and one or more second electrodes in the battery. The second connector passes between the flap and the case such that a portion of the flap is between the first connector and the second connector.