Secondary Battery Head Cover Assembly Space Optimization
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Solution Overview
Problem
The existing secondary battery assembly methods require protrusions that occupy internal space, complicating the assembly process and reducing battery capacity due to the need for a top bracket and lower plastic protrusions.
Innovation Solution
A secondary battery head cover assembly that integrates a top connection sheet with two naked battery core insulation sheets, eliminating the need for a top bracket by using a head cover with an electrode pole through hole and hot-melt connections, allowing for a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a top bracket and lower plastic protrusions are used to connect the head cover, then structural integrity is ensured, but internal space is occupied and assembly complexity increases
Solution Approach 1:
The patent integrates the top bracket and lower plastic into a unified connection structure where the lower plastic is formed as an integral part of the head cover assembly. This merging eliminates the need for separate protruding components, thereby saving internal space while maintaining structural integrity through the integrated design.
Solution Approach 2:
The patent extracts and eliminates the unnecessary protrusion features from the design. By removing the need for the lower plastic to protrude downward and the top bracket to protrude upward, the design achieves a compact configuration that occupies minimal internal space while still providing adequate connection functionality.
2Stability of the object's composition
If protrusions are used for connection, then structural stability is achieved, but battery capacity is reduced due to space occupation
Solution Approach 1:
By merging the connection functions into the head cover assembly itself without requiring additional protruding elements, the design maintains structural stability while maximizing the available volume for active materials, thereby improving battery capacity.
Solution Approach 2:
The patent transitions from a three-dimensional protruding connection structure to a two-dimensional planar connection approach, where connections are established through surfaces and interfaces rather than volumetric protrusions, thus preserving internal space for capacity enhancement.
3Reliability
If separate top bracket and lower plastic components are used, then connection reliability is ensured, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple components into fewer integrated parts, reducing the number of manufacturing steps and assembly operations required. The integrated head cover assembly with built-in connection features simplifies the manufacturing process while maintaining connection reliability through proven design principles.
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 saves internal space, improving energy density by eliminating the need for protrusions and simplifying the assembly process while maintaining effective insulation and structural integrity.
Implementation Method 1
the top connection sheet is fixed with the lower plastic by hot melt
Data Source
AI summary
The present application relates to a secondary battery head cover assembly, a secondary battery including the same and an assembling method thereof. The secondary battery head cover assembly includes a head cover and an insulation structure, the insulation structure includes a top connection sheet and two naked battery core insulation sheets, an electrode pole is provided on the head cover, and an electrode pole through hole is provided at a position on the top connection sheet corresponding to the electrode pole, the top connection sheet is located below the head cover and is connected to the head cover. The secondary battery includes the secondary battery head cover assembly and the naked battery core, the naked battery core is located below the top connection sheet, and the two naked battery core insulation sheets wrap the side and bottom surfaces of the naked battery core.