Power Battery Top Cover Assembly Deformable Plate Design
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Solution Overview
Problem
The existing top cover plate structure for power batteries faces issues such as increased safety risks due to reduced deformation space, electrolyte residue-induced short circuits, and structural complexity, which complicates assembly and sealing performance.
Innovation Solution
A top cover assembly design that includes a deformable plate connected to a second connecting block via a through-hole, with an upper and lower sealing piece and insulating piece configuration that prevents electrolyte flow and ensures gas discharge, featuring a gas-guide hole and sealing areas to manage internal pressure and prevent external short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the deformable plate deforms to electrically connect with the connecting block, then the safety function is improved, but the space between the deformable plate and connecting block is reduced, causing air pressure increase that influences normal deformation and increases safety risk
Solution Approach 1:
The patent introduces a gas discharge channel that segments the sealed cavity into distinct regions, allowing gas to be discharged during deformation. This prevents pressure buildup that would otherwise hinder the deformable plate's movement and maintain safety risks, while preserving the compact sealed structure.
2Ease of manufacture
If electrolyte residues are present around the electrode terminal, then the production process is simplified, but electrolyte may flow into the deformable plate and electrically connect the connecting block with the deformable plate, causing external short circuit risk
Solution Approach 1:
The patent introduces an insulating structure as an intermediary between the electrolyte-containing environment and the deformable plate/connecting block. This insulating barrier prevents electrolyte from causing electrical connection, allowing the production process to tolerate electrolyte residues without compromising safety.
3Reliability
If the insulating piece for electrode terminal is used to seal and fix the second electrode terminal, then the sealing performance is improved, but the insulating piece may loosen, age and get injured, leading to loss of sealing performance and electrolyte leakage
Solution Approach 1:
The patent designs the insulating structure with built-in compensation mechanisms that anticipate aging and loosening. The structure maintains sealing effectiveness even as the insulating piece degrades over time, preventing electrolyte leakage without requiring frequent replacement.
4Reliability
If separate structures are disposed to solve specific problems in the top cover plate, then the safety and sealing functions are improved, but the structural complexity and assembling difficulties are significantly increased
Solution Approach 1:
The patent merges multiple functions (deformable plate, gas discharge, insulation, sealing) into an integrated top cover assembly structure. This unified design achieves the required safety and sealing functions while reducing the number of separate components and simplifying assembly, directly addressing the complexity issue.
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 enhances safety by preventing electrolyte flow and ensuring smooth gas discharge, while maintaining a compact and integrated structure with simplified assembly, addressing the structural complexity and safety concerns of the existing designs.
Implementation Method 1
the deformable plate provided on the top cover plate deforms when the pressure of the internal gas generated in the cell reaches a certain value
Implementation Method 2
so that the first electrode assembly is electrically connected with the second electrode assembly, so as to form an external short circuit of the cell
Implementation Method 3
a through-hole and a gas-guide hole are defined in the second insulating piece
Implementation Method 4
the second electrode terminal penetrates through the top cover plate and the second insulating piece, and is insulated from the top cover plate
Data Source
AI summary
Provided is a top cover structure for power battery, including a first electrode assembly, a second electrode assembly, a top cover plate electrically connected with the first electrode assembly, and a deformable plate attached to the top cover plate; the second electrode assembly includes a second electrode terminal, a second connecting block, a second insulating piece in which a via-hole and an gas-guide hole are defined, an upper sealing piece arranged between the second insulating piece and the second connecting block and including a sealing area for deforming space and a sealing area for electrode terminal, and a lower sealing piece arranged between the second insulating piece and the top cover plate and enclosing the via-hole for deformable plate. The sealing area for deforming space encloses the via-hole and the gas-guide hole, the sealing area for electrode terminal enclose the second electrode terminal.