Battery Cell Top Cover Assembly for Shorter Tabs and Easier Welding
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Solution Overview
Problem
The assembling process of battery cells is complex, with separate welding processes required for tabs on both sides of the cell, leading to increased difficulty and excessive tab length due to interference with the housing during welding.
Innovation Solution
A top cover assembly that includes an insulation member, adapter, and end covers, allowing simultaneous welding of tabs before loading into the housing, with a second end cover sealing the opening to improve assembly efficiency and reduce tab length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate welding processes are carried out for tabs on both sides before and after loading into housing, then welding can be completed, but the assembling process becomes complex and tab length becomes excessive
Solution Approach 1:
The top cover assembly is divided into multiple components: insulation member, adapter, first end cover, and pole. This segmentation allows the welding process to be performed on the adapter and pole assembly separately before integration into the housing, simplifying the overall assembling process while ensuring reliable welding connections.
Solution Approach 2:
The adapter and pole are assembled and welded together in advance before being integrated into the housing with the cell. This preliminary action allows the welding process to be completed outside the housing, avoiding interference and reducing the complexity of the overall assembling process.
2Ease of operation
If tab is made long to pull out of housing for welding, then welding can be performed, but tab length becomes excessive and welding difficulty increases
Solution Approach 1:
The adapter serves as an intermediary component that connects the tab to the pole. The tab is welded to the adapter, which is then connected to the pole. This intermediary structure allows welding to be performed on a manageable length of tab outside the housing, eliminating the need for excessive tab length while maintaining welding accessibility.
3Reliability
If welding is performed after cell is loaded into housing, then connection is established, but housing interferes with welding process
Solution Approach 1:
The adapter and pole are assembled and welded together in advance before being integrated into the housing with the cell. This preliminary action allows the welding process to be completed outside the housing, avoiding interference from the housing while ensuring reliable connection establishment.
Solution Approach 2:
The welding process is extracted from the housing integration step and performed separately on the adapter and pole assembly before final assembly. This separation eliminates the interference of the housing during welding while maintaining the reliability of the connection.
Data Source
AI summary
A top cover assembly, a battery cell, an assembling method for a battery cell, and an electric device. The top cover assembly includes: a top cover loading-into-housing assembly, comprising an insulation member, an adapter, a first end cover and a pole connected to the adapter, wherein the projection contour of the first end cover falls within an area defined by the outer edge contour of the insulating member. A projection contour of the first end cover is located within a region defined by an outer edge contour of the insulation member, and the pole sequentially penetrates the insulation member and the first end cover.