Battery Top Cover Tab Connection Layout to Prevent Short Circuits
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Solution Overview
Problem
The existing secondary batteries suffer from reduced energy density due to the staggered arrangement of the pole of the end cover assembly and the tab of the electrode assembly, resulting in a large gap that is not conducive to efficient utilization of internal space.
Innovation Solution
The energy-storage apparatus incorporates a design with a first connector connected to a first tab and a first pole, featuring a sealing plug that supports the extension section of the tab, and a top cover with a liquid-injection hole and protrusion to prevent bending and short circuits, while optimizing the assembly process for improved space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pole of the end cover assembly and the tab of the electrode assembly are arranged in a staggered manner and connected by a connector, then the connection is achieved, but the gap between them increases, reducing energy density
Solution Approach 1:
The patent merges the connector with the end cover assembly by integrating the connection function directly into the end cover structure. The end cover now directly connects to the tab of the electrode assembly without requiring a separate connector, eliminating the gap that would otherwise exist between the pole and the tab. This integration maintains reliable electrical connection while maximizing space utilization and improving energy density.
Solution Approach 2:
The end cover assembly is designed to perform multiple functions: it serves as both the protective cover and the electrical connection component. By making the end cover universally functional (both structural and electrical), the patent eliminates the need for a separate connector, thereby reducing the gap and improving energy density while maintaining connection reliability.
2Reliability
If a connector is used to connect the pole and the tab, then the electrical connection is established, but the internal space utilization decreases due to the large gap
Solution Approach 1:
The patent combines the connector function with the end cover assembly, eliminating the separate connector component. The end cover now directly interfaces with the tab, removing the gap that would otherwise occupy internal space. This merging maintains electrical connection reliability while significantly improving space utilization within the battery housing.
3Device complexity
If the extension section of the tab is left unsupported, then the assembly is simpler, but the tab may bend and cause short circuits
Solution Approach 1:
The support function for the tab's extension section is integrated into the end cover assembly structure. The end cover includes a specific structural feature that naturally supports and constrains the extension section, preventing bending and potential short circuits. This integration maintains assembly simplicity while ensuring reliability through the unified design.
Data Source
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AI summary
An energy-storage apparatus and an electricity-consumption device are disclosed in the present disclosure. The energy-storage apparatus includes a first tab, a first pole, a first connector, and a lower plastic assembly. The first connector is connected to the first tab and a flange portion of the first pole. A top cover defines a liquid-injection hole. A sealing plug includes a plug body. The lower plastic assembly at least includes a first-lower-plastic-member body. The first-lower-plastic-member body defines a hollow hole. In a thickness direction of the lower plastic assembly, the first-lower-plastic-member body is mounted on the top cover. The liquid-injection hole is positioned facing towards and is in communication with the hollow hole. The sealing plug seals the liquid-injection hole. The plug body extends through the liquid-injection hole and the hollow hole, and protrudes from a second surface of the first-lower-plastic-member body. The first connector is mounted on the second surface of the first-lower-plastic-member body. The first tab is fixed to the first connector. In a length direction of the first connector, an extension section of the first tab exceeds an end of the first connector and blocks the hollow hole. The plug supports the extension section. A gap is defined between the extension section and the second surface. A short circuit caused by contact between the first tab and the top cover is prevented.