Battery End Cover Assembly Scabbard Sealing Flange
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Solution Overview
Problem
Current lithium ion battery cells for electric and hybrid vehicles are deficient in power output, reliability, and safety, with issues such as short-circuits and explosions due to unreliable electrochemical cell core constructions and interconnections.
Innovation Solution
A battery system design featuring a coiled core assembly with a protective shell and end cover assembly that includes a connector and sealing material to enhance safety and reliability, along with a method of preparing the end cover assembly using a cover plate, scabbard, and connector, and a sealing material that forms a protective flange to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrochemical cell core constructions and interconnections are used, then the battery system can be manufactured with existing technology, but the power output is insufficient and reliability is poor due to short-circuits and explosions
Solution Approach 1:
The end cover assembly is segmented into distinct functional components: a cover plate for structural support, a scabbard for connector housing and alignment, and a sealing material for isolation. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability and safety.
Solution Approach 2:
The scabbard acts as an intermediary element between the cover plate and the connector, providing a protective housing that isolates the connector and ensures proper alignment. This intermediary structure prevents direct contact between potentially harmful elements and improves overall system reliability.
2Reliability
If simple sealing methods are used, then the manufacturing process is easier, but short-circuits and explosions can occur due to inadequate sealing
Solution Approach 1:
A sealing material is used to create a flexible yet effective seal within the scabbard structure. This sealing layer prevents short-circuits and contamination while accommodating minor dimensional variations, ensuring reliability without requiring complex rigid sealing mechanisms.
Solution Approach 2:
The sealing material is installed beforehand within the scabbard structure to provide a pre-established protective barrier against short-circuits and environmental contamination, ensuring reliability before the battery is assembled and put into service.
3Power
If conventional battery cell designs are used, then the battery system can be produced with existing manufacturing processes, but the power output is insufficient to meet vehicle demands
Solution Approach 1:
The connector is nested within the scabbard, which is in turn mounted on the cover plate. This nested arrangement maximizes space utilization and allows for compact yet powerful battery cell designs that can deliver high power output while maintaining a manageable form factor.
Solution Approach 2:
The end cover assembly introduces a new dimensional approach to battery construction by emphasizing the end-cap structure with integrated sealing and connection features, rather than focusing solely on the cylindrical or prismatic cell body. This dimensional shift enables improved power density and output.
4Reliability
If basic protective measures are used, then the manufacturing cost is lower, but the battery system is unsafe and unreliable for vehicle applications
Solution Approach 1:
Multiple protective functions are merged into a single integrated end cover assembly structure. The cover plate, scabbard, and sealing material work together as a unified protective system that prevents short-circuits, contains potential failures, and ensures safety without requiring separate redundant protective devices.
Solution Approach 2:
The end cover assembly utilizes composite construction combining rigid structural elements (cover plate, scabbard) with flexible sealing materials. This composite approach provides comprehensive protection against mechanical damage, electrical short-circuits, and environmental contamination, ensuring vehicle-grade safety and reliability.
Data Source
AI summary
An end cover assembly for a battery comprises a cover plate; a scabbard mounted on the cover plate; a connector; and a sealing material. The cover plate comprises an opening. The scabbard comprises an interior channel. The opening is in communication with the channel. The connector is disposed in the interior channel and protrudes from the scabbard. The sealing material is disposed in the interior channel and extends beyond the upper portion of the scabbard and wraps around the outside of the scabbard to form a protective flange.