Cylindrical Battery Insulation Assembly for Displacement-Tolerant Fitting
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Solution Overview
Problem
Existing insulation assemblies for cylindrical batteries face challenges in assembly difficulty, operational displacement tolerance, and safety due to deformation and folding of insulating caps during assembly, leading to potential safety hazards.
Innovation Solution
An insulation assembly design featuring an insulating cap with a neck, skirt, and corner part, and an insulating tape that forms a specific angle with the rolled core, equipped with cut slits to facilitate alignment and deformation, providing additional insulation and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an existing insulating cap is fitted to the rolled core during assembly, then electrical insulation is provided, but displacement during assembly causes deformation and folding of the insulating cap, creating safety hazards
Solution Approach 1:
The insulating cap is divided into multiple parts: a first insulating cap portion and a second insulating cap portion. This segmentation allows each portion to independently accommodate displacement without causing folding, while still providing complete insulation coverage when assembled together on the rolled core.
Solution Approach 2:
The insulating cap portions are designed with flexible connection structures that allow dynamic adjustment during assembly. The portions can flexibly adapt to positional variations and displacement during the assembly process, maintaining proper insulation without rigid deformation.
2Stability of the object's composition
If downward pressure is applied during assembly, then the insulating cap is secured to the rolled core, but the rolled core is abutted first causing the insulating cap to fold and interfere with the rolled core
Solution Approach 1:
The segmented insulating cap structure acts as a cushioning mechanism that absorbs assembly pressure before it reaches the rolled core. The multiple portions distribute the downward pressure evenly, preventing concentrated forces that would cause folding or damage to the rolled core.
Solution Approach 2:
The insulating cap portions are designed with flexible characteristics that allow them to deform elastically under pressure without permanent folding. This flexibility enables the cap to be secured to the rolled core while maintaining its protective function and preventing interference with the rolled core structure.
3Reliability
If the insulating cap is designed to fit closely to the end face of the rolled core, then insulation is improved, but assembly precision requirements increase and operational displacement tolerance decreases
Solution Approach 1:
By dividing the insulating cap into multiple portions, the system provides insulation coverage without requiring each individual portion to fit precisely. The segmented structure accommodates manufacturing tolerances and assembly variations while maintaining continuous insulation between the rolled core and outer housing.
Solution Approach 2:
The design changes the geometric parameters of the insulating cap portions to create overlap and clearance zones. This allows the portions to be positioned with standard manufacturing precision while still achieving effective insulation coverage, increasing operational displacement tolerance.
Data Source
AI summary
A cylindrical battery with an insulation assembly, the cylindrical battery includes an outer housing; a rolled core accommodated in the outer housing; and an insulation assembly. The insulation assembly is positioned between the outer housing and the rolled core, and is configured to separate a portion of the rolled core from the outer housing.