Battery Top Cover Insulating Member for Crush Protection Under Vibration
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Solution Overview
Problem
The contact area between the lower plastic member and the cell body in a secondary battery is relatively small, leading to high pressure on the cell body during vibration or inversion, which can cause crush damage and affect performance and safety.
Innovation Solution
The secondary battery design includes an insulating member that increases the contact area between the cell body and other components by attaching the insulating member to the lower plastic member, using snap-fit structures for positioning, and optimizing the contact areas to ensure adequate insulation and current-carrying capacity while minimizing crush damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the lower plastic member directly contacts the cell body with small contact area, then the structural simplicity is maintained, but the pressure on the cell body increases causing crush damage
Solution Approach 1:
The patent introduces an insulating member as an intermediary component between the lower plastic member and the cell body. This insulating member has a larger contact area than the lower plastic member alone, thereby distributing the pressure over a larger area and preventing crush damage to the cell body while maintaining structural simplicity through the use of a single intermediate component
2Stress or pressure
If the contact area between lower plastic member and cell body is increased, then the pressure distribution is improved, but the device complexity increases
Solution Approach 1:
The patent merges the functions of pressure distribution and electrical insulation into a single insulating member component. This component simultaneously provides a large contact area for pressure distribution and electrical insulation properties, thereby improving pressure distribution without significantly increasing device complexity through multiple separate components
3Reliability
If the insulating member is added to increase contact area, then the protection against crush damage is improved, but the manufacturing complexity increases
Solution Approach 1:
The insulating member is designed with self-positioning features such as positioning steps and snap-fit structures that enable automatic alignment and secure attachment during assembly. This self-service design reduces the need for complex positioning procedures and manual adjustment, thereby improving reliability through better positioning while minimizing increases in manufacturing complexity
Data Source
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AI summary
A secondary battery includes an electrode assembly and a top cover assembly (500), the electrode assembly includes a cell body (100) and an insulating member (300), and the top cover assembly includes a lower plastic member (510). The insulating member (300) is provided on the lower plastic member (510) and in contact with the cell body (100), to increase a contact area between the cell body (100) and other components, and reduce the pressure imposed on the cell body (100) under conditions such as vibration. A side of the lower plastic member (510) near the insulating member (300) is provided with a positioning step (511) and the insulating member (300) can be mated to the positioning step (511), to form a relative positioning between the lower plastic member (510) and the insulating member (300).