Battery Lead Insulating Cover Segmented Design
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Solution Overview
Problem
The existing battery manufacturing process is time-consuming and labor-intensive due to the need to insert and connect leads into insulating members, which complicates the connection between electrode terminals and the battery case while ensuring insulation.
Innovation Solution
A battery design featuring a lead insulating cover with interchangeable components that form a space to accommodate the lead, ensuring insulation and simplifying the manufacturing process by allowing the lead to be inserted after terminal connection, with engagement mechanisms to secure the cover components and regulate movement for accommodating changes in electrode plate specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead is inserted into the hole of the insulating member and connected to the electrode terminal, then the insulating property between the lead and the battery case is ensured, but the connection work becomes time-consuming and increases manufacturing time and effort
Solution Approach 1:
The insulating member and the lead insulating cover are merged into a single integrated component. The lead insulating cover is formed by joining a first cover component and a second cover component, which together with the insulating member form a unified structure that provides both insulation and lead accommodation functions, eliminating the need for separate insulating member installation steps
Solution Approach 2:
The lead insulating cover is designed to accommodate the lead in advance before the lead is connected to the electrode terminal. The first cover component and second cover component are prepared with engagement portions that will join together, creating a pre-formed insulating structure with a through-hole for the lead, which simplifies the subsequent connection process
2Ease of manufacture
If the lead insulating cover is formed by joining multiple cover components, then the ease of manufacture is improved, but the device complexity increases due to multiple components and engagement mechanisms
Solution Approach 1:
The lead insulating cover is segmented into a first cover component and a second cover component, each with specific engagement portions. This segmentation allows for easier manufacturing of individual components and simplifies assembly, as each component can be independently formed and then joined through the engagement portions to create the complete insulating cover structure
Data Source
AI summary
A battery includes: an electrode stacked body; a battery case that accommodates the electrode stacked body; positive and negative electrode terminals that are provided so as to communicate inside and outside of the battery case with each other; a lead that electrically connects tabs of the electrode stacked body to the electrode terminals; and an insulated lead insulating cover in which a space is formed so that the lead enters and a terminal through-hole is formed so that one end of the electrode terminal enters the space therethrough. An insulated lead insulating cover includes a first cover component and a second cover component that cooperatively form the space and the terminal through-hole with each other, and the first cover component and the second cover component respectively include engagement portions engaging removable with each other.