Battery Cell End Cap Groove-Protrusion Assembly Against Bending Gaps
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Solution Overview
Problem
The challenge of improving the pass rate of battery assembly is exacerbated by the bending deformation of the end cap due to its weight, leading to gaps between the end cap and the casing during assembly, particularly in battery cells with a length-to-width ratio greater than or equal to 500 mm and thickness less than or equal to 0.3 mm.
Innovation Solution
The end cap is equipped with a first protrusion, and the insulating member within the battery cell features a corresponding first groove, allowing them to cooperate and restrict deformation, thereby enhancing the fit between the end cap and the casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the end cap is made thin (thickness ≤ 0.3 mm) to reduce weight and material usage, then the weight and material consumption decrease, but the end cap undergoes bending deformation due to its own weight, causing gaps between the end cap and casing during assembly
Solution Approach 1:
The end cap is segmented by adding protrusions that divide the continuous structure into supported sections. These protrusions act as intermediate support points that prevent the thin end cap from bending uniformly across its entire surface, thereby maintaining assembly precision while keeping the end cap thin and lightweight.
Solution Approach 2:
The end cap utilizes a composite structure combining the base thin material with reinforced protrusion elements. This composite design allows the end cap to maintain overall thinness for weight reduction while the protrusion regions provide localized structural support to prevent bending deformation during assembly.
2Length of moving object
If the end cap dimensions are increased (length ≥ 500 mm) to meet battery cell size requirements, then the battery cell capacity increases, but the end cap experiences greater bending deformation due to increased span and self-weight
Solution Approach 1:
The long end cap is divided into multiple supported sections by protrusions positioned at strategic locations. This segmentation reduces the effective span of each section, preventing excessive bending deformation while maintaining the overall length required for large battery cell capacity.
Solution Approach 2:
The protrusions act as intermediary support elements between the end cap and the internal structure. These intermediaries provide localized support points that stabilize the end cap shape across its entire length, preventing the thin end cap from sagging or deforming under its own weight over the long span.
3Ease of manufacture
If traditional assembly methods are used without deformation restriction structures, then the assembly process is simple, but the pass rate of battery assembly is low due to gaps caused by end cap bending
Solution Approach 1:
The protrusions are pre-formed on the end cap before assembly, creating built-in deformation restriction structures in advance. This preliminary action ensures that the end cap maintains its shape during assembly without requiring complex external fixtures or multi-step alignment procedures, thereby maintaining assembly simplicity while improving pass rate.
Solution Approach 2:
The end cap's own protrusions serve the dual function of structural reinforcement and alignment guides during assembly. The protrusions automatically engage with corresponding features on the casing, enabling the end cap to self-align and self-restrain against bending deformation, improving assembly reliability without complicating the manufacturing process.
Data Source
AI summary
A battery cell, a battery, and an electric apparatus are provided, which can improve the pass rate of assembly of batteries. The battery cell includes: a casing having an opening; an end cap closing the opening; and an insulating member disposed within the casing, where one of the insulating member and the end cap is provided with a first groove, and the other thereof is provided with a first protrusion, the first groove and the first protrusion cooperating with each other.