Battery Cell Top Cover Assembly for Universal Module Integration
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Solution Overview
Problem
The existing battery module designs require different integral harness separators for varying battery cell sizes and arrangements, leading to increased research and manufacturing costs due to the need for new molds and production lines.
Innovation Solution
A top cover assembly is introduced, featuring a separator plate integrated with a top cover plate, using protrusion portions and blind holes for fixation, and electrode connecting structures to stabilize the electrode connecting sheet, allowing for consistent assembly across different battery cell arrangements without requiring new molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different integral harness separators are used for varying battery cell sizes and arrangements, then the battery module can accommodate different configurations, but the research and manufacturing costs increase due to the need for new molds and production lines
Solution Approach 1:
The separator plate is designed with a universal structure that can accommodate different battery cell sizes and arrangements through adjustable clamping mechanisms. The plate includes multiple clamping regions with independent clamping members that can be positioned to suit various cell configurations, eliminating the need for different separator plates for different battery module designs.
Solution Approach 2:
The separator plate is divided into multiple independent clamping regions, each with its own clamping members. This segmentation allows each region to be independently adjusted and configured for different battery cell arrangements, while the overall plate structure remains the same, reducing manufacturing complexity.
2Adaptability or versatility
If different integral harness separators are used for varying battery cell arrangements, then the battery module can accommodate different configurations, but the production time increases due to the need for new production lines
Solution Approach 1:
The separator plate serves multiple functions across different battery module configurations using a single standardized design. The universal plate can be used across multiple production lines without requiring line-specific molds or fixtures, maintaining high production efficiency while accommodating design variations.
Solution Approach 2:
The clamping members on the separator plate are designed to be adjustable and reconfigurable, allowing the same separator plate to adapt to different battery cell arrangements dynamically during assembly, eliminating the need for retooling production lines.
3Reliability
If an integral harness separator is used to isolate the battery module, then short circuit prevention is achieved, but the assembly complexity increases
Solution Approach 1:
The separator plate integrates multiple functions into a single component: it provides electrical isolation to prevent short circuits, mechanically clamps the electrode connecting sheets, and serves as a structural support element. This merging reduces the number of separate components and simplifies the overall assembly process.
Solution Approach 2:
The separator plate performs multiple functions simultaneously - electrical insulation, mechanical clamping, and structural support - in a single standardized component that can be used across different battery module configurations, reducing both complexity and assembly steps.
Data Source
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AI summary
A top cover assembly of a battery cell, a battery cell (1), and a battery module. The top cover assembly of the battery cell (1) includes: a separator plate (1) and a top cover assembly (12). The separator plate (11) is provided with sampling channel(s) (111) for accommodating a sampling member. The top cover plate (12) is configured for sealing an electrode assembly (15) of the battery cell (1) into the battery housing (14), where the top cover plate (12) is provided below the separator plate (11), and the separator plate (11) is fixed to the top cover plate (12). Distinctive from prior art, the top cover assembly and the battery cell may be applied in battery modules using different assembly methods, which greatly improves the efficiency of the battery module assembly with strong the adaptability and high the versatility, and effectively reduces the research and manufacturing costs of a battery system.