Battery Cover with Integrated Caps and Gas Channel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery covers face challenges such as complex capping of filling openings, safety risks due to accessible caps, misalignment issues between secondary and primary covers, and the risk of frit being wetted during manufacturing, along with issues related to centralized degassing systems like the 'pump effect' and frit impregnation.
Innovation Solution
A cover design featuring a primary cover with conical openings and a gas collection channel leading to a frit seat, a secondary cover with integrated or separately attached caps for alignment adjustment, and a duct with a reduced cross-section to prevent electrolyte drops from reaching the frit, ensuring tamper-resistance and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secondary cover is used to cover filling openings, then safety is improved by preventing cap removal, but misalignment between covers occurs due to material shrinkage
Solution Approach 1:
The patent merges the secondary cover and caps into a single integrated component. The caps are directly formed as part of the secondary cover structure, eliminating the need for separate caps that could misalign. This integration ensures that the filling openings are properly covered while maintaining manufacturing precision, as the caps and cover are molded together as one piece rather than assembled from separate parts.
2Ease of operation
If caps are made accessible from outside, then ease of operation is improved for user access, but safety is worsened due to potential removal by users
Solution Approach 1:
The patent implements a nested structure where the secondary cover with integrated caps is positioned over the primary cover. The caps are nested within the secondary cover structure, creating a layered protection system. This nested arrangement allows the caps to remain accessible for normal operation while being protected by the secondary cover structure that prevents unauthorized removal or tampering.
3Object-generated harmful factors
If a centralized degassing system with lateral vents is used, then gas venting is improved, but the pump effect causes electrolyte accumulation at channel ends
Solution Approach 1:
The patent changes the dimensional arrangement of the degassing system by positioning the frit seat and vent opening at a different location and orientation. Instead of lateral vents at the ends of a linear channel, the system uses a vertically oriented frit seat with a vent opening on the side surface of the cover. This dimensional change eliminates the pump effect by preventing electrolyte accumulation at channel ends, as the gas flow path now passes through the frit material rather than accumulating at terminal points.
4Object-generated harmful factors
If frit is present on the cover during manufacturing, then degassing function is improved, but frit becomes impregnated with electrolyte during construction
Solution Approach 1:
The patent applies preliminary action by pre-forming the frit seat structure and positioning the frit material before the battery filling operation. The frit is installed in the dedicated seat during cover assembly, before electrolyte is poured into the cells. This preliminary placement ensures the frit is in position to perform its degassing function while preventing it from becoming impregnated with electrolyte during construction, as the frit is already secured in its functional position before any electrolyte handling occurs.
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 simplifies battery manufacturing, enhances safety by preventing cap removal and misalignment, reduces the risk of electrolyte reaching the frit, and maintains frit dryness during production, resulting in a reliable, cost-effective, and aesthetically pleasing maintenance-free battery cover.
Implementation Method 1
i which liquid electrolyte can flow under the action of gravity
Implementation Method 2
a duct (613) with a reduced cross-section with respect to the gas collection channel (7), to prevent liquid electrolyte drops from reaching the frit
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Cover for electrolytic batteries, comprising a primary cover (1) adapted to be fixed on a container of electrolytic cells and provided with a plurality of openings (41, 51) for filling with electrolyte for respective electrolytic cells of the container, the walls of the openings (41, 51) being crossed transversely by a common gas collection channel (7), the cover comprising at least one secondary cover (2) which can be fixed on the upper face (3) of the primary cover (1) to cover the openings (41, 51), the secondary cover (2) comprising a plurality of caps (42, 52), which protrude from it and can engage respectively in the openings (41, 51) of the primary cover (1), each one of the caps (42, 52) being provided with a radial expansion (422, 522) adapted to engage in a gas-tight manner on the wall of the respective opening (41, 51) between the common gas collection channel (7) and the upper face (3) of the primary cover (1), the caps (42, 52) being not accessible when the secondary cover (2) is fixed on the upper face (3) of the primary cover (1).