Compact Battery End Cover Assembly for Higher Energy Density
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Solution Overview
Problem
Current secondary batteries face challenges with small capacity and low energy density due to limitations in battery structure.
Innovation Solution
The secondary battery design includes an end cover assembly with a top cover, electrode terminal, and insulating second fixing member, which reduces the protruding height of the electrode terminal and optimizes the end cover assembly's structure for a more compact design, increasing battery capacity and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery structure is optimized to reduce end cover assembly volume, then battery capacity and energy density increase, but the electrode terminal mounting complexity increases
Solution Approach 1:
The end cover assembly is segmented into multiple functional components: top cover, electrode terminal, insulating fixing member, sealing member, and connection sheet. Each component performs a specific function, allowing the assembly to achieve compact volume while maintaining manageable complexity through modular design.
Solution Approach 2:
The insulating fixing member is nested within the end cover assembly, with the electrode terminal passing through it. The connection sheet is nested within the first recessed portion of the top cover. This nesting arrangement maximizes space utilization and reduces the overall volume of the end cover assembly.
2Quantity of substance
If the electrode terminal protruding height is reduced, then battery energy density increases, but the sealing requirement becomes more stringent
Solution Approach 1:
A sealing member is introduced as an intermediary component between the electrode terminal and the end cover assembly. This sealing member ensures reliable sealing while allowing the electrode terminal to have minimal protruding height, thus resolving the conflict between energy density and sealing performance.
Solution Approach 2:
The sealing member is positioned locally at the interface between the electrode terminal and the end cover assembly, providing enhanced sealing quality precisely where needed. This localized approach ensures reliable sealing without affecting the overall compact design.
3Quantity of substance
If the end cover assembly volume is reduced, then battery capacity increases, but the electrode terminal insulation requirement becomes more critical
Solution Approach 1:
An insulating fixing member is introduced as an intermediary component that provides electrical insulation for the electrode terminal. This insulating fixing member is integrated into the compact end cover assembly, ensuring reliable insulation while maintaining the reduced volume necessary for high battery capacity.
4Quantity of substance
If the end cover assembly is designed to be more compact, then battery energy density increases, but the manufacturing precision requirement increases
Solution Approach 1:
The end cover assembly is divided into separate components that can be manufactured independently with standard precision tolerances. The segmentation allows each component to be manufactured separately and then assembled, reducing the cumulative precision requirements compared to a monolithic compact design.
Data Source
AI summary
The present disclosure provides a secondary battery, a battery pack, and an energy storage box. The secondary battery includes an end cover assembly. The end cover assembly includes a top cover, a top patch, and an electrode terminal. The end cover assembly is designed to have a more compact structure, which reduces a space occupied, thereby improving a capacity and energy density of the secondary battery.