Battery Cell End Cap Structure to Prevent Wire Harness Stress
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Solution Overview
Problem
In battery systems, particularly in inverted cells, wire harnesses are often damaged due to the height of the pressure relief boss exceeding that of the insulating member, leading to stress concentration and potential failure.
Innovation Solution
An end cap design featuring a pressure relief boss that does not extend beyond the insulating member's outer surface, with a protective member covering the pressure relief region to prevent damage to wire harnesses, and an insulating member attached to the cap body to minimize stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure relief boss is made taller to improve pressure relief function, then the pressure relief capability is improved, but the wire harnesses are pressed and damaged causing stress concentration
Solution Approach 1:
An insulating member is introduced as an intermediary component between the pressure relief boss and the wire harnesses. This insulating member has a height greater than that of the pressure relief boss, creating a protective barrier that prevents direct contact between the boss and the wire harnesses, thereby eliminating stress concentration while preserving the pressure relief function.
2Ease of operation
If the pressure relief boss extends beyond the insulating member, then the pressure relief region is more accessible, but the wire harnesses are damaged resulting in battery failure
Solution Approach 1:
The insulating member serves as a mediator that allows the pressure relief boss to maintain its functional accessibility while preventing harmful interactions with wire harnesses. The insulating member's extended height creates a protective zone that preserves battery reliability.
Solution Approach 2:
The insulating member provides localized protection specifically in the region where wire harnesses are vulnerable to the pressure relief boss. This local quality enhancement addresses the specific problem area without requiring changes to the overall battery structure.
3Object-affected harmful factors
If the pressure relief boss height is reduced to avoid pressing wire harnesses, then wire harness protection is improved, but the pressure relief function may be compromised
Solution Approach 1:
Rather than reducing the pressure relief boss height which would compromise its function, an insulating member is introduced as a mediator. This allows the boss to maintain its original height and pressure relief capability while the insulating member prevents direct contact with wire harnesses, thus protecting them without sacrificing pressure relief functionality.
Data Source
AI summary
An end cap includes a cap body, a pressure relief boss, and an insulating member. The cap body has a pressure relief region and an outer surface. In a thickness direction of the cap body, the pressure relief boss is arranged on the outer surface in a protruding manner and surrounds the pressure relief region. The insulating member is attached to the outer surface. In the thickness direction, the pressure relief boss does not extend beyond, in a direction facing away from the outer surface, an end of the insulating member that faces away from the outer surface.