End Cap Assembly Structure for Airtight Battery Pole Sealing
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Solution Overview
Problem
Existing end cap assemblies in energy storage devices face issues with air tightness due to material expansion and contraction, leading to potential air leaks and safety hazards during long-term use.
Innovation Solution
The end cap assembly features a connecting member with grooves and stepped surfaces that enhance airtightness by ensuring uniform pressing force distribution and preventing welding defects, thereby improving the accuracy of airtightness detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the end cap assembly uses a simple structure without grooves or stepped surfaces, then the manufacturing process is easier and device complexity is reduced, but the sealing performance deteriorates due to non-uniform pressing force distribution and potential air leaks
Solution Approach 1:
The connecting member incorporates grooves at specific locations to create localized sealing zones. These grooves are positioned where pressing force is needed most, creating non-uniform local properties that enhance sealing at critical interfaces without requiring complex structures throughout the entire component.
Solution Approach 2:
The connecting member is divided into multiple sections with different geometries, including grooves and stepped surfaces. This segmentation allows each section to perform specific functions: grooves for sealing, stepped surfaces for uniform pressure distribution, and different diameter sections for connecting various components.
2Measurement precision
If the end cap assembly undergoes airtightness detection during manufacturing, then the safety and service life are improved, but the detection accuracy is insufficient when material expansion and contraction occur during long-term use
Solution Approach 1:
The grooves and stepped surfaces are built into the connecting member during manufacturing, creating pre-formed sealing structures that maintain their function throughout the service life. These features ensure that pressing force is uniformly distributed from the beginning, preventing welding defects and maintaining sealing integrity during material expansion and contraction over time.
3Manufacturing precision
If the connecting member has a uniform cross-sectional area, then the manufacturing process is simpler, but the pressing force distribution is non-uniform causing welding defects and reduced sealing performance
Solution Approach 1:
The connecting member features an asymmetric design with a groove on one side and a stepped surface structure. The groove is positioned at a specific location rather than being symmetrically distributed, allowing the structure to compensate for non-uniform pressing forces by concentrating sealing capability where needed most.
Solution Approach 2:
The cross-sectional area of the connecting member varies along its length, creating a stepped structure with different diameter sections. This parameter change allows the connecting member to adapt to different interface requirements: larger sections for structural support and smaller sections for precise positioning and sealing, enabling uniform pressing force distribution throughout the assembly.
Data Source
AI summary
An end cover assembly, an energy storage device and electricity-consumption equipment. The end cover assembly includes an end plate, a pole and a connecting member. The end plate has a first surface and a second surface disposed opposite to each other along a thickness direction thereof. The end plate further has a first pole hole penetrating the end plate. The pole has a first pole section and a second pole section. An outer circumferential surface of the first pole section is connected with the outer circumferential surface of the second pole section through an annular stepped surface. The first pole section is inserted into the first pole hole. The connecting member is located at a side where the annular stepped surface of the pole is located, and has a second pole hole coaxially arranged with the first pole hole.