Battery Cell End Cap Groove-Protrusion Assembly Fit Control
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Solution Overview
Problem
The issue of low pass rate in battery assembly due to bending deformation of the end cap during the assembly process, particularly when the end cap's thickness is less than or equal to 0.3 mm and length is greater than or equal to 500 mm, leading to difficulty in achieving a good fit with the casing.
Innovation Solution
The end cap is provided with a first protrusion, and the insulating member inside the battery cell is equipped with a first groove, allowing them to cooperate and restrict the deformation of the end cap, thereby improving the fit between the end cap and the casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the end cap is made thinner to reduce weight, then the weight of the end cap is reduced, but the end cap deforms due to its own weight causing assembly failure
Solution Approach 1:
The end cap is segmented by adding protrusions that divide the continuous plate into sections. These protrusions act as structural reinforcements that prevent deformation while maintaining the overall thin design. The protrusions create multiple smaller support zones instead of a single large unsupported area.
Solution Approach 2:
The end cap transitions from uniform thickness to non-uniform thickness with localized protrusions. The protrusions are strategically positioned at critical areas where deformation is most likely to occur, providing localized reinforcement only where needed rather than increasing the weight of the entire end cap.
2Quantity of substance
If the end cap is made longer to increase battery capacity, then the energy storage is improved, but the end cap bends due to its own weight making assembly difficult
Solution Approach 1:
The long end cap is segmented by protrusions that create multiple shorter effective spans. This segmentation reduces the bending moment in each section, allowing the end cap to be longer overall while maintaining sufficient stiffness for precise assembly. The protrusions act as intermediate support points.
Solution Approach 2:
The end cap uses a composite structure combining a thin base plate with thicker protrusion regions. This composite design allows the majority of the end cap to remain thin for weight reduction while the protrusion regions provide the necessary structural support for long-span stability and assembly precision.
Data Source
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AI summary
A battery cell (20), a battery (10), and an electric apparatus are provided, which can improve the pass rate of assembly of batteries (10). The battery cell (20) includes: a casing (212) having an opening; an end cap (211) closing the opening; and an insulating member (23) disposed within the casing (212), where one of the insulating member (23) and the end cap (211) is provided with a first groove (231), and the other thereof is provided with a first protrusion (213), the first groove (231) and the first protrusion (213) cooperating with each other.