Battery End Cap Assembly With Layered Bonding and Insulation
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Solution Overview
Problem
Existing cover plate structures in battery technologies suffer from poor connection reliability and a risk of falling off during manufacturing and use, primarily due to inadequate bonding and insulation, which can lead to electrical abnormalities and structural instability.
Innovation Solution
An end cap assembly comprising a cover plate, adhesive member, and insulation member, where the adhesive member is thinner than the insulation member, ensuring secure bonding and fixation, and the insulation member provides effective separation and isolation, reducing the overall thickness and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an injection molding part is used to bond the terminal to the cover plate, then the manufacturing process is simple, but the connection reliability is poor and the structure may fall off during use
Solution Approach 1:
The original single injection molding part is segmented into two separate components: an adhesive member and an insulation member. This segmentation allows each component to perform its specific function optimally - the adhesive member provides strong bonding through adhesive material while the insulation member provides electrical isolation and structural support, thereby resolving the contradiction between manufacturing simplicity and connection reliability.
Solution Approach 2:
The invention uses composite material structure where the adhesive member is made of adhesive material (such as polypropylene, polyethersulfone, or polyamide) bonded to the cover plate, combined with an insulation member made of insulating material. This composite approach ensures both strong adhesion and reliable electrical insulation, improving connection reliability while maintaining manufacturing feasibility through standardized bonding processes.
2Reliability
If the adhesive member is made thicker to ensure bonding strength, then connection reliability improves, but the overall assembly thickness increases
Solution Approach 1:
The invention uses composite material structure where the adhesive member is made of adhesive material (such as polypropylene, polyethersulfone, or polyamide) bonded to the cover plate, combined with an insulation member made of insulating material. This composite approach ensures both strong adhesion and reliable electrical insulation, improving connection reliability while maintaining manufacturing feasibility through standardized bonding processes.
Solution Approach 2:
The invention optimizes the thickness parameter of the adhesive member by specifying that H1 (adhesive member thickness) should be less than H2 (insulation member thickness), with H2 ≤ 3H1. This parameter optimization ensures adequate bonding strength while controlling overall assembly thickness, resolving the contradiction between bonding strength and assembly compactness.
3Device complexity
If traditional cover plate structure is used without dedicated insulation member, then device complexity is reduced, but electrical insulation and safety are compromised
Solution Approach 1:
The original single injection molding part is segmented into two separate components: an adhesive member and an insulation member. This segmentation allows each component to perform its specific function optimally - the adhesive member provides strong bonding through adhesive material while the insulation member provides electrical isolation and structural support, thereby resolving the contradiction between manufacturing simplicity and connection reliability.
Solution Approach 2:
The insulation member serves multiple functions simultaneously: it provides electrical insulation between the terminal and cover plate, maintains structural integrity of the assembly, and contributes to the overall mechanical strength. This multi-functionality approach improves electrical insulation reliability while keeping the structure efficient and not excessively complex.
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 improves connection reliability and reduces the risk of disengagement, while minimizing the assembly's thickness and eliminating the need for environmentally harmful materials, thus ensuring stable and efficient operation.
Implementation Method 1
an adhesive member, wherein the adhesive member is bonded to the cover plate
Data Source
Figure 1~2
Figure 3~4
AI summary
An end cap assembly, a battery apparatus, and a power consumption device are provided. The end cap assembly includes a cover plate, an adhesive member, and an insulation member. The cover plate is provided with a first mounting hole. The adhesive member is bonded to the cover plate. The adhesive member is provided with a second mounting hole. The second mounting hole corresponds to the first mounting hole. The insulation member is disposed on a side of the cover plate facing away from the adhesive member. The insulation member is provided with a third mounting hole. The third mounting hole corresponds to the first mounting hole. A thickness of the adhesive member is H1 and a thickness of the insulation member is H2, satisfying the following: H1<H2. Through the foregoing arrangement, connection reliability of the end cap assembly is improved, and a risk of falling off during manufacturing and use is reduced.