Secondary Battery Top Cover Assembly Protrusion Design
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Solution Overview
Problem
The existing top cover assemblies of secondary batteries have poor energy density due to inefficient use of space and residue welding stress from conduction blocks, which affects the safety and performance of the batteries.
Innovation Solution
A top cover assembly with a protrusion on the top cover plate that forms an accommodation chamber, where a deformable plate covers the chamber, eliminating the need for a conduction block and enhancing energy density by utilizing space more effectively and improving deformation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conduction block is used to facilitate series or parallel connection, then electrical conduction is improved, but energy density deteriorates due to poor space utilization
Solution Approach 1:
The patent merges the conduction block function with the top cover plate by integrating a conduction layer directly onto the top cover plate surface. This eliminates the separate conduction block component while maintaining electrical conduction capability, thereby improving space utilization and energy density.
Solution Approach 2:
The top cover plate is given multiple functions: it serves as both the structural cover and the electrical conduction element through the integrated conduction layer. This multi-functionality removes the need for separate conduction blocks, optimizing space and improving energy density.
2Reliability
If a conduction block is welded to the top cover plate, then electrical connection is established, but safety deteriorates due to residue welding stress affecting deformable plate performance
Solution Approach 1:
The patent extracts the welding process from the assembly by using a conduction layer that is integrated with the top cover plate through non-welding methods (such as coating or lamination). This eliminates the harmful welding residue stress while maintaining electrical connection functionality.
Solution Approach 2:
The conduction layer acts as an intermediary between the top cover plate and the deformable plate, providing electrical connection without requiring direct welding. This intermediary layer prevents welding stress from being transmitted to the deformable plate, preserving its safety performance.
3Reliability
If the space between top cover plate and second terminal assembly is filled with conduction block, then electrical conduction is achieved, but volume efficiency deteriorates
Solution Approach 1:
The conduction function is merged into the top cover plate itself through the integrated conduction layer, eliminating the need for separate conduction blocks that occupy valuable space. This merging approach maintains electrical conduction while maximizing volume efficiency.
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 solution increases the inner space of the secondary battery, enhances energy density, and improves safety by avoiding the negative effects of welding residue stress, while maintaining the ability to facilitate series or parallel connections.
Implementation Method 1
the deformable plate (21) is configured to deform in response to an increase of an internal pressure of the secondary battery
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
Provided are a top cover assembly (100) and a secondary battery containing the same. The top cover assembly (100) includes a top cover plate (10) and a first terminal assembly (20); the top cover plate (10) includes a main body (11) and a protrusion (12) connected to the main body (11), the protrusion (12) protrudes beyond an upper surface of the main body (11), an accommodation chamber (13) is defined below the protrusion (12), the protrusion (12) faces the accommodation chamber (13), the first terminal assembly (20) includes a deformable plate which is connected to the top cover plate (10) and covers the accommodation chamber (13). Such solution can sufficiently utilize space between the upper surface of the top cover plate (10) and the upper surface of the second terminal assembly (30), improve deformation resistance and strength of the top cover plate (10), and keep the secondary battery safe.