Battery End Cover Assembly With Insulated Terminal Mounting Hole
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Solution Overview
Problem
Existing battery cell designs face safety issues due to short-circuit connections between electrode terminals and top cover sheets, which compromise safety performance.
Innovation Solution
An end cover assembly with a top cover sheet featuring a mounting hole and an insulating layer on its inner wall surface, along with additional insulating members and layers, is designed to prevent short circuits by increasing the creepage distance and forming a closed insulating space between the electrode terminal and the top cover sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode terminal is directly connected to the top cover sheet for electrical connection, then the electrical connectivity is improved, but the safety performance deteriorates due to short-circuit risk
Solution Approach 1:
An insulating layer is introduced as an intermediary between the electrode terminal and the top cover sheet. This insulating layer prevents direct electrical contact while allowing the electrode terminal to pass through the mounting hole, thus eliminating the short-circuit risk while maintaining electrical connectivity function.
Solution Approach 2:
The top cover sheet is segmented into different functional zones: a mounting hole region for electrical connection and an insulating layer region for safety isolation. The insulating layer is specifically positioned on the inner wall surface facing the mounting hole, creating distinct functional segments that address both connectivity and safety requirements.
2Reliability
If an insulating layer is added on the inner wall surface of the top cover sheet, then the safety performance is improved by preventing short circuits, but the device complexity increases
Solution Approach 1:
The insulating layer is applied locally only on the inner wall surface of the top cover sheet facing the mounting hole, rather than covering the entire top cover sheet. This localized application provides the necessary safety isolation exactly where the electrode terminal contacts the cover sheet, while minimizing the addition of structural complexity and material usage.
Data Source
AI summary
An end cover assembly comprises: a top cover sheet, comprising a first surface and a second surface which are arranged opposite to each other along the thickness direction of the top cover sheet, a mounting hole running through the top cover sheet along the thickness direction thereof, and an inner wall surface that faces the mounting hole; the top cover sheet is provided with a first insulating layer, and at least part of the first insulating layer is located on the inner wall surface.