Battery Cover Assembly with Offset Weld Joints for Lower Resistance
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Solution Overview
Problem
Conventional lithium-ion battery electrode pole structures result in solder joints between the electrode pole and battery cell tab being the same height as those between the electrode pole and external electrical connectors, affecting electrical conductivity and increasing the risk of defective welding.
Innovation Solution
A cover assembly with an electrode plate and insulators, where the through holes for the electrodes are misaligned to prevent same-height solder joints, ensuring insulation and stability during welding, and allowing for different electrode lengths to match the battery cell tab, reducing internal resistance and improving power performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrode pole is perpendicular to the top cover with same-height solder joints, then the structure is simple and easy to manufacture, but the electrical conductivity is affected and welding quality deteriorates
Solution Approach 1:
The patent transitions from a single vertical dimension (perpendicular electrode pole) to a multi-dimensional arrangement by tilting the electrode plate at an angle and positioning solder joints at different heights. This spatial reconfiguration in multiple dimensions allows both solder joints to be positioned optimally without interfering with each other, resolving the contradiction between manufacturing simplicity and electrical conductivity.
Solution Approach 2:
The patent segments the electrode connection structure into distinct components: the electrode plate, insulators with through-holes, and separately positioned solder joints. By segmenting the connection path and allowing each component to be independently optimized, the design achieves both ease of manufacture and reliable electrical conductivity without the interference present in conventional same-height configurations.
2Device complexity
If the electrode pole is perpendicular to the top cover, then the structure is compact, but the welding process is affected and defective welding rate increases
Solution Approach 1:
By introducing angular orientation and vertical separation, the patent moves the welding process from a constrained single-plane operation to a multi-dimensional configuration. This allows welders to access both solder joints without interference, improving welding quality while maintaining reasonable structural complexity through the use of a tilted electrode plate and strategically positioned insulators.
Solution Approach 2:
The insulators with through-holes serve as intermediaries that facilitate the tilted electrode plate configuration. These insulators enable the electrode to be positioned at an optimal angle for welding while maintaining electrical insulation, thus improving welding quality without significantly increasing overall structural complexity.
3Ease of operation
If the electrode plate connects to battery cell tab and external connector at same height, then the alignment is simple, but the conductivity performance deteriorates
Solution Approach 1:
The patent resolves the alignment contradiction by moving from a single-plane (2D) alignment to a multi-dimensional (3D) configuration. The electrode plate is tilted at an angle, and solder joints are positioned at different heights, creating a spatial arrangement that maintains alignment simplicity through standardized mounting while achieving superior conductivity performance through optimized current path geometry.
Solution Approach 2:
The patent employs asymmetric positioning of the solder joints at different heights on the tilted electrode plate. This asymmetric configuration optimizes the electrical current path and reduces resistance by allowing each connection point to be positioned independently for optimal conductivity, while still maintaining ease of operation through standardized insulator and mounting hole patterns.
Data Source
AI summary
Disclosed are a cover assembly, a battery and a battery pack. The cover assembly includes a cover plate, an electrode plate, a first insulator and a second insulator. The electrode plate is disposed on the cover plate, and the electrode plate includes a first electrode portion and a second electrode portion electrically connected to each other. The first insulator is disposed between the electrode plate and the cover plate, and the second insulator is disposed on one side of the electrode plate away from the cover plate. The area of the first insulator corresponding to the first electrode portion is provided with a first through hole, the area of the second insulator corresponding to the second electrode portion is provided with a second through hole, and the orthographic projections of the first through hole and the second through hole on the cover plate do not overlap each other.