Battery Cover Labyrinth Structure for Electrolyte Leakage Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery cover designs face issues with inefficient gas discharge and electrolyte leakage, particularly when the battery is tilted or turned over, due to complex constructions and corrosion of springs, leading to increased production costs and leakage risks.
Innovation Solution
A battery cover design featuring a labyrinth structure formed by upper and lower covers with gas discharge ports and micro-holes, along with recovery ports that prevent electrolyte leakage by guiding it back into the battery case, even when the battery is tilted or turned over, using a simplified construction that eliminates the need for additional parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery cover designs are used, then gas discharge function is provided, but electrolyte leakage occurs when battery is tilted or turned over
Solution Approach 1:
The battery cover is divided into multiple functional regions: gas discharge holes for gas venting, recovery ports for electrolyte collection, and labyrinth structures for guiding electrolyte flow. This segmentation allows each region to perform its specific function independently, preventing electrolyte leakage while maintaining gas discharge capability without requiring complex external components
Solution Approach 2:
The recovery ports are nested within the battery cover structure, with the labyrinth structure integrated into the cover walls. The electrolyte recovery channel is formed by the spatial relationship between the recovery port and the labyrinth structure, creating a compact nested arrangement that eliminates the need for separate external recovery devices
2Reliability
If complex construction with additional parts is used, then electrolyte leakage resistance is improved, but production costs increase
Solution Approach 1:
The gas discharge function and electrolyte recovery function are merged into a single integrated battery cover structure. The cover simultaneously provides gas discharge holes for venting, recovery ports for electrolyte collection, and labyrinth structures for flow guidance, eliminating the need for separate external recovery devices and reducing production costs
Solution Approach 2:
The battery cover is designed as a multi-functional component that performs gas discharge, electrolyte recovery, and leakage prevention all in one structure. The labyrinth structure serves multiple purposes: guiding electrolyte flow to recovery ports, preventing direct leakage paths, and maintaining structural integrity, thereby reducing the need for additional specialized parts
3Reliability
If recovery ports are arrayed to prevent leakage when tilted, then electrolyte recovery is improved, but gas discharge efficiency may be affected
Solution Approach 1:
The cover is segmented into distinct functional zones: gas discharge holes positioned in regions accessible to gas but not electrolyte, and recovery ports positioned to collect electrolyte that flows through the labyrinth structure. This spatial segmentation ensures gas and electrolyte have separate discharge paths, eliminating the problem of electrolyte leaking through gas ports
Solution Approach 2:
The labyrinth structure acts as an intermediary that directs electrolyte flow toward recovery ports while allowing gas to reach discharge holes unimpeded. The tortuous path of the labyrinth structure slows electrolyte movement and guides it into recovery ports, while gas, being less viscous and under pressure, can still efficiently reach the discharge holes through the same structure
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 design significantly enhances electrolyte leakage resistance and recovery efficiency, minimizing production costs and preventing electrolyte loss during tilting or overturning by utilizing a labyrinth structure and integrated recovery ports.
Implementation Method 1
a sealed assembly structure of upper and lower covers of a battery case is configured in such a way that it forms a labyrinth structure that can allow an electrolyte to move upward and downward, thereby increasing an electrolyte leakage resistance
Implementation Method 2
gas discharge holes and micro-holes are formed so as to easily discharge gas from the battery case
Implementation Method 3
electrolyte recovery ports are arrayed in such a way that the electrolyte can be prevented from leaking from the battery case even when the battery case is turned over or is tilted to one side
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery cover for prevention of electrolyte leakage is disclosed. In the battery cover, a sealed assembly structure of upper and lower covers of a battery case is configured in such a way that it forms a labyrinth structure that can allow an electrolyte to move upward and downward, thereby increasing an electrolyte leakage resistance of the battery case. Further, gas discharge holes and micro-holes are formed in the battery cover, and so the battery cover can easily discharge gas from the battery case. In the battery cover, electrolyte recovery ports are arrayed in such a way that the electrolyte can be prevented from leaking from the battery case even when the battery case is turned over or tilts to one side.