Battery Cell End Cap Notch Fit to Prevent Metal Scrapings
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Solution Overview
Problem
In the production of battery cells, unstable production errors lead to interference fits between the end cap and the case, causing scratching and metal scrapings to fall into the case, which can result in internal short circuits and safety issues.
Innovation Solution
The end cap is fitted onto the case using a protrusion that matches a notch, reducing scratching and preventing metal scrapings from entering the case, with the notch and protrusion designed to facilitate secure mating and prevent laser penetration during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end cap is fitted into the opening of the case using interference fit, then the end cap can be securely attached to the case, but metal scrapings are generated by scratching between the end cap and the case which may fall into the case and cause internal short circuit
Solution Approach 1:
A protrusion structure is introduced as an intermediary element between the end cap and the case. The protrusion fits into a corresponding notch on the case, serving as a mediator that guides the assembly process and prevents direct scratching contact between the end cap and case surfaces, thereby eliminating metal scraping generation while maintaining secure attachment
Solution Approach 2:
The protrusion and notch are pre-designed with specific geometric shapes that guide the end cap into the correct position before final attachment. This preliminary action ensures proper alignment and prevents scratching during the fitting process, allowing the end cap to be securely attached without generating metal scrapings
2Reliability
If the notch depth is increased to prevent laser penetration during welding, then laser safety is improved, but the structural integrity of the end cap may be compromised
Solution Approach 1:
The notch depth is optimized to a specific range that provides sufficient laser blocking capability at the critical welding location while maintaining adequate material thickness elsewhere in the end cap to preserve overall structural integrity. This local quality adjustment ensures both laser welding safety and end cap strength
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
This design enhances the safety of battery cells by minimizing metal scrapings and preventing internal short circuits, ensuring a secure and damage-free assembly process.
Implementation Method 1
the end cap is fitted on the case by mating the protrusion with the notch, which can effectively reduce the metal scrapings generated by scratching between the end cap and the case
Implementation Method 2
during use by laser welding between the notch and the protrusion
Data Source
AI summary
Described are a battery cell, a battery and a device using a battery cell as a power source, wherein the battery cell comprises a case and an end cap, wherein the case is provided with an opening, the end cap is used for covering the opening and is in sealed connection with the case, one of the case or the end cap is provided with a notch, the other is provided with a protrusion, the protrusion is provided within the notch and matches the shape of the notch, and the end cap is fitted on the case by mating the protrusion with the notch. The end cap of the battery cell of the present application is fitted on the case by mating the protrusion with the notch, which can effectively reduce the metal scrapings generated by scratching between the end cap and the case from falling into the case.