Battery Cell End Cap Convex Contact for Reliable Tab Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The end cap of a battery cell often fails to make proper contact with the tab due to structural limitations of the housing, leading to poor performance and potential short circuits.
Innovation Solution
The end cap includes a convex part that protrudes beyond the housing limit, ensuring good contact with the tab and increasing the contact area, while an insulation member isolates the cap body from the housing to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the end cap is designed to cover the opening of the housing, then the end cap can be positioned and secured, but the housing structure limits the end cap's ability to contact the tab
Solution Approach 1:
The end cap is segmented into a cap body and a first convex part, where the first convex part protrudes from the cap body to contact the first tab. This segmentation allows the contact function to be separated from the covering function, enabling reliable tab contact without requiring complex housing structures.
Solution Approach 2:
The first convex part extends in a direction away from the cap body towards the electrode assembly, creating a new spatial dimension for contact. This dimensional extension allows the end cap to contact the tab without increasing the overall footprint or requiring complex housing modifications.
2Area of stationary object
If the first convex part protrudes beyond the first limit part to contact the tab, then contact area is increased, but the cap body must be positioned away from the electrode assembly
Solution Approach 1:
The end cap structure is divided into the cap body (for covering) and the first convex part (for contact). This allows the contact area to be increased through the protruding first convex part while keeping the cap body positioned optimally for covering the opening, without requiring the cap body to be closer to the electrode assembly.
Solution Approach 2:
The first convex part acts as an intermediary element between the cap body and the tab. It extends from the cap body to make contact with the tab, increasing the contact area while maintaining the cap body's optimal positioning relative to the electrode assembly.
3Reliability
If the cap body is positioned away from the electrode assembly to allow first convex part contact, then tab contact is ensured, but insulation from the housing is required
Solution Approach 1:
The first insulation member acts as an intermediary element between the cap body and the housing. It prevents direct contact between the conductive cap body and housing, ensuring electrical insulation without requiring complex insulation structures. The first insulation member can be a simple gasket or insulating ring that fits between the cap body and housing.
Solution Approach 2:
The insulation function is extracted as a separate component (first insulation member) rather than being integrated into the cap body or housing structures. This simplifies the overall design by making insulation a distinct, easily replaceable element.
Data Source
AI summary
A battery cell includes an electrode assembly, a housing, and an end cap. The electrode assembly includes a tab. The housing has an opening and includes a limit part, and is configured to accommodate the electrode assembly. The end cap includes a cap body and a convex part. The cap body is configured to cover the opening. In a thickness direction of the end cap, the cap body is located at one side of the limit part away from the electrode assembly. The limit part is configured to limit the cap body from moving relatively to the housing towards the electrode assembly. The convex part protrudes from an inner surface of the cap body towards the electrode assembly. The convex part is configured to go beyond the limit part away from the cap body, so that the convex part is pressed against the tab.