Battery Top Cover Terminal Welding for Simpler Assembly
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Solution Overview
Problem
The traditional assembly method of battery top covers for new energy vehicles is complex and costly due to the need for intricate connections between the terminal and top cover, which complicates the design and manufacturing process, leading to low efficiency and high production costs.
Innovation Solution
A battery top cover assembly featuring a conductive terminal structure with connectors that are welded to the top cover plate, utilizing a positioning groove and concave-convex fits to ensure secure and efficient assembly, reducing the reliance on material properties of the top cover and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is assembled into the connecting hole and fixedly connected to the top cover by welding, riveting or injection molding, then the terminal is securely fixed on the top cover, but the process becomes relatively complicated and the design and manufacturing process becomes cumbersome
Solution Approach 1:
The patent divides the top cover into two separate components: the top cover body and the terminal assembly. The terminal assembly is pre-assembled with the terminal and fixing structure, then integrated into the top cover body through the connecting hole. This segmentation simplifies the overall connection structure and makes the assembly process more straightforward while maintaining secure fixation.
2Reliability
If the terminal is assembled into the connecting hole and then fixedly connected by welding, riveting or injection molding, then the terminal is securely fixed, but the manufacturing and molding efficiency becomes low and production cost increases
Solution Approach 1:
The terminal assembly is pre-assembled with the terminal and the fixing structure (including the fixing portion and limiting portion) before being installed into the top cover body. This preliminary assembly allows for standardized production of the terminal component, improving manufacturing efficiency and reducing production costs while ensuring reliable connection through the pre-designed fixing mechanism.
3Reliability
If complex connection structures are used to fix the terminal on the top cover, then the terminal is securely fixed, but material properties of the top cover must be carefully considered making the design process cumbersome
Solution Approach 1:
The fixing structure is designed with universal applicability, where the fixing portion can be universally adapted to different top cover materials and the limiting portion provides a standardized engagement mechanism. This multi-functional design reduces the need to carefully consider specific material properties for each application, simplifying the design and manufacturing process while maintaining reliable fixation across different material types.
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
This solution simplifies the design and manufacturing of battery top covers, improves sealing performance, prevents axial movement of the terminal, and enhances torque stability, thereby reducing production costs and improving efficiency.
Implementation Method 1
outer peripheral walls of the connectors are in contact with and welded with an inner peripheral wall of the connecting hole
Data Source
AI summary
The disclosure provides a battery top cover assembly, comprising top cover plate and a conductive terminal structure. Connectors are formed on a bottom surface of the conductive terminal structure, and the connectors are fitted in a connecting hole of the top cover plate. Outer peripheral walls of the connectors are in contact with and welded with inner peripheral walls of the connectors, so that the conductive terminal structure is fixedly connected to the top cover plate. The independently manufactured and molded terminal structure is welded with the connecting hole of the top cover plate for fixing, which simplifies design and manufacturing process, thereby improving production efficiency and reducing production cost.