Battery Cell End Cap Structure for Precise Housing Alignment
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Solution Overview
Problem
Existing battery cell assembly processes face challenges with positioning difficulties, misalignment, and reduced sealing performance due to the lack of effective positioning mechanisms between the end cap and housing, leading to increased friction and deformation risks.
Innovation Solution
The introduction of a protruding portion on the end cap with a corresponding recessed portion to facilitate alignment and stress relief during assembly, reducing friction and deformation risks while enhancing sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a protruding portion is added to the end cap to improve positioning, then assembly efficiency is improved, but device complexity increases
Solution Approach 1:
The end cap is segmented into a cap body and a protruding portion, where the protruding portion is a separate functional element that extends from the cap body to engage with the housing. This segmentation allows the positioning function to be isolated in the protruding portion while the cap body maintains its sealing function, improving assembly efficiency without significantly complicating the overall structure.
Solution Approach 2:
The protruding portion acts as an intermediary element between the end cap and the housing. It facilitates the connection and positioning by engaging with a corresponding recessed portion in the housing, enabling accurate alignment and secure attachment while simplifying the assembly process.
2Manufacturing precision
If the protruding portion is made rigid to maintain positioning accuracy, then manufacturing precision is improved, but the risk of deformation and particle generation increases
Solution Approach 1:
The material parameters of the protruding portion are optimized to achieve a balance between rigidity and flexibility. The protruding portion is made from a material or with a structure that provides sufficient stiffness for positioning accuracy while incorporating flexibility to absorb assembly stresses and prevent deformation and particle generation.
Solution Approach 2:
The design incorporates stress-relief features in the protruding portion that act as cushioning elements before harmful deformation or particle generation can occur. These features allow controlled deformation or stress absorption during assembly, preventing the protruding portion from generating particles or causing damage to the housing.
3Measurement precision
If the protruding portion extends deeply into the housing to improve positioning, then positioning accuracy is improved, but friction and extrusion force increase
Solution Approach 1:
The protruding portion extends partially into the housing to the minimum necessary depth to achieve accurate positioning and secure attachment. This partial extension is sufficient for the positioning function while avoiding excessive depth that would increase friction and extrusion forces during assembly and operation.
Solution Approach 2:
The surface properties of the protruding portion are optimized locally to reduce friction. The outer surface of the protruding portion may have reduced roughness or specialized coating in the region that contacts the housing, minimizing friction and extrusion forces while maintaining positioning accuracy.
4Ease of manufacture
If the end cap structure is simplified to reduce manufacturing complexity, then ease of manufacture is improved, but positioning accuracy and sealing performance deteriorate
Solution Approach 1:
The end cap is designed with a segmented structure where the protruding portion is integrated with or attached to the cap body. This segmentation allows the protruding portion to be formed or attached using simple processes while maintaining its positioning function, achieving a balance between manufacturing simplicity and positioning accuracy.
Solution Approach 2:
The protruding portion and cap body are merged into a single integrated component or securely attached assembly, eliminating the need for separate positioning elements. This merging simplifies manufacturing by reducing the number of parts and assembly steps while maintaining the positioning and sealing functions through the integrated design.
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
Improves assembly efficiency, reduces particle generation, and enhances safety by minimizing deformation and friction between the end cap and housing components.
Implementation Method 1
a recessed portion or recess is formed on the end cap at a position corresponding to the protruding portion, and the recessed portion is recessed from an outer surface of the cap body toward the electrode assembly and configured to release a stress while the protruding portion extends into the housing
Data Source
AI summary
A battery cell may include: a housing, on which an opening is made; an electrode assembly, accommodated in the housing; and an end cap, configured to fit and cover the opening. The end cap may include a cap body and a protruding structure around the cap body, the protruding structure may protrude from an inner surface of the cap body toward the electrode assembly, and at least a part of the protruding portion may be located in the housing and configured to fit with the housing. A recess may be formed on the end cap at a position corresponding to the protruding structure, and the recess may be recessed from an outer surface of the cap body toward the electrode assembly and configured to release a stress while the protruding portion extends into the housing.