Battery Cell Top Cover Assembly With Universal Separator Plates

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Solution Overview

Problem

The existing battery module technologies require different integral harness separators for varying battery cell sizes and arrangements, leading to increased research time, labor costs, and manufacturing expenses due to the need for multiple injection molds and production lines.

Innovation Solution

A top cover assembly for battery cells, where a separator plate is directly fixed to the top cover plate, eliminating the need for an integral separator plate, allowing for adaptable assembly methods across different battery module configurations without altering the separator plate structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an integral harness isolating plate is used for the battery module, then short circuit prevention between electrode connection sheet and sampling member is achieved, but device complexity and manufacturing cost increase due to requiring multiple injection molds for different battery cell arrangements

Engineering Contradiction:

Improveshort circuit preventionVSAvoidseparator plate structure variety

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The separator plate is divided into a first separator plate and a second separator plate that are separately disposed on opposite sides of the battery cell. Each separator plate can be independently designed and manufactured, allowing them to be standardized components that work with different battery cell arrangements without requiring custom integral harness isolating plates for each configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first and second separator plates are designed as universal components that can be applied to multiple battery cell arrangements and configurations. By separating the isolating function into two standardized plates rather than one custom integral plate, the same separator plate designs can serve multiple battery module configurations, reducing the number of unique molds needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If different integral harness separators are designed for varying battery cell sizes and arrangements, then proper isolation is achieved, but research time and labor costs increase

Engineering Contradiction:

Improveisolation effectivenessVSAvoidresearch and development time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By segmenting the isolating function into separate first and second separator plates, the design process is simplified and standardized. This segmentation allows for reusable design templates that can be quickly adapted to different battery cell sizes and arrangements, significantly reducing the research and development time compared to designing unique integral harness separators for each configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator plates are designed as pre-configured standardized components with isolation features already incorporated. This preliminary design approach allows the same separator plate structures to be repeatedly used across different battery cell arrangements without requiring new design and validation cycles for each configuration, thereby reducing overall R&D time.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If multiple injection molds and production lines are used for different separator plates, then specific battery cell arrangements are supported, but manufacturing expenses increase

Engineering Contradiction:

Improvebattery cell arrangement compatibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The isolation system is segmented into separate first and second separator plates that can be manufactured using standard molds. This segmentation enables the use of fewer, more versatile molds compared to producing custom integral harness separators for each battery cell arrangement, thereby reducing manufacturing expenses while maintaining adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first and second separator plates are designed as universal components that can be used across multiple battery cell arrangements and configurations. This universality allows a single mold design to produce separator plates suitable for various battery module configurations, eliminating the need for multiple specialized injection molds and production lines, thus reducing manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12002972B2Top cover assembly, battery cell, battery module and manufacturing methods therefor

Publication Date: 2024.06.04 JIANGSU CONTEMPORARY AMPEREX TECH LTD

AI summary

A top cover assembly of a battery cell, a battery cell, and a battery module. The top cover assembly of the battery cell includes: a separator plate and a top cover assembly. The separator plate is provided with sampling channel(s) for accommodating a sampling member. The top cover plate is configured for sealing an electrode assembly of the battery cell into the battery housing, where the top cover plate is provided below the separator plate, and the separator plate is fixed to the top cover plate.