Battery Lid Insulation Member Elastic Deformation
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Solution Overview
Problem
Existing terminal-equipped battery case lids deform significantly during manufacturing, leading to gaps between the battery case and lid body when closed, resulting in variations in welding penetration depth and potential welding defects.
Innovation Solution
A terminal-equipped battery case lid design where the insulation member is configured to elastically deform and counteract the bending of the lid body, reducing deformation by using a force-receiving insulation portion that becomes planar when caulked, thereby minimizing the curvature of the lid body and preventing gaps during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the lid body, insulation member and external terminal are fastened together by inserting the caulking member into the lid through-holes and applying a caulking load, then the components are securely fastened, but the lid body is deformed and bent in the opposite direction to the load
Solution Approach 1:
The patent applies preliminary anti-action by pre-forming the insulation member with a curved surface that bulges in the opposite direction to the expected lid body deformation. This pre-formed curvature creates a counteracting force that compensates for the bending caused by the caulking load, thereby reducing the net deformation of the lid body while maintaining secure fastening of the components
2Ease of manufacture
If the lid body is significantly deformed during manufacturing, then the caulking fastening is achieved, but gaps are generated between the battery case and lid body when closed
Solution Approach 1:
The insulation member is pre-formed with a curved surface that anticipates and counteracts the lid body deformation during caulking. This preliminary configuration ensures that when the caulking load is applied, the insulation member's elastic deformation compensates for the bending, preventing gap formation between the battery case and lid body while maintaining ease of manufacturing through the caulking process
3Ease of manufacture
If the lid body has curvature due to deformation, then the caulking fastening is completed, but variations in welding penetration depth and welding defects occur
Solution Approach 1:
By pre-forming the insulation member with a curved surface that bulges opposite to the expected lid body bending, the patent creates a compensating mechanism that reduces lid body deformation during caulking. This results in a flatter lid body surface that ensures uniform welding penetration depth and prevents welding defects, thereby improving welding quality and reliability while completing the caulking fastening process
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
The design reduces the deformation of the lid body, preventing gaps between the battery case and lid body, minimizing welding defects and variations in penetration depth, and enhancing the reliability of the sealing process.
Implementation Method 1
the portion of the insulation member is elastically deformed and the surface of the portion of the insulation member facing the lid body is brought into close contact with the surface of the lid body
Data Source
AI summary
A portion of an insulation member makes contact with a surface of a lid body by receiving a caulking force from a caulking member either directly or indirectly via another member. When not receiving the caulking force, a surface of the portion of the insulation member facing the lid body becomes a curved surface which indicates a curve bulging in a load direction of a caulking load on a cut plane, the cut plane cutting the portion of the insulation member in a longitudinal direction of the lid body. When kept in the fastened state by receiving the caulking force, the portion of the insulation member is elastically deformed and the surface of the portion of the insulation member facing the lid body is brought into close contact with the surface of the lid body.