End Cover Fuse Isolation for Battery Safety
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Solution Overview
Problem
Secondary batteries face safety issues due to the risk of the fuse section being re-connected after fusion, leading to potential fires or explosions when the fuse section is wetted by electrolyte, causing the main circuit to fail to cut off.
Innovation Solution
The end cover assembly design includes a terminal assembly with a fuse section positioned outside the electrode lead-out hole, protected by an insulating component and sealing component, which prevents re-connection of the fuse section with the electrode assembly, reducing the likelihood of electrical reconnection and subsequent fires or explosions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the fuse section is positioned inside the electrode lead-out hole, then the battery structure is more compact, but the fuse section may be wetted by electrolyte after fusion causing re-connection and safety hazards
Solution Approach 1:
The fuse section is extracted from the interior of the electrode lead-out hole and repositioned to the exterior surface of the end cover assembly. This extraction removes the fuse section from the hazardous environment where electrolyte could cause re-connection, while maintaining overall battery compactness through optimized external positioning.
Solution Approach 2:
An insulating component is introduced as an intermediary between the fuse section and the electrode lead-out hole. This insulating component prevents direct contact between the fuse section and electrolyte, providing a protective barrier that eliminates the re-connection risk while allowing the fuse section to maintain its functional position.
2Device complexity
If the fuse section is exposed to electrolyte, then the battery structure is simpler, but the fuse section may be re-connected after fusion causing fires or explosions
Solution Approach 1:
An insulating component serves as a mediator between the fuse section and the electrolyte environment. This intermediary element provides necessary isolation without significantly complicating the overall battery structure, preventing harmful re-connection while maintaining design simplicity.
Solution Approach 2:
A sealing component in the form of a flexible seal or gasket is used to isolate the fuse section from electrolyte exposure. This thin-film approach provides effective protection against fire and explosion risks while adding minimal structural complexity to the battery assembly.
3Reliability
If the fuse section is isolated from electrolyte using insulating and sealing components, then the safety against re-connection is improved, but the device complexity increases
Solution Approach 1:
The insulating component and sealing component are merged into an integrated assembly that combines insulation and sealing functions in a single structural unit. This merging reduces the number of separate parts and simplifies the end cover assembly while maintaining effective isolation of the fuse section from electrolyte.
Solution Approach 2:
The insulating component is designed to perform multiple functions simultaneously: providing electrical insulation, sealing against electrolyte, and structurally supporting the fuse section. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving reliable fuse section isolation.
Data Source
AI summary
The disclosure relates to an end cover assembly, a secondary battery, a battery pack and an electric device. An end cover assembly for a secondary battery includes: an end cover; a first terminal including a first connecting section and a second connecting section disposed along a radial direction; a second terminal including a third connecting section, a fuse section and a fourth connecting section sequentially connected along the radial direction; along an axial direction, orthographic projections of the first and third connecting sections at least partially overlap with each other, one of the first and third connecting sections is configured to connect with a busbar, the other is configured to connect with an electrode assembly, the fourth connecting section is configured to connect with the second connecting section; and an insulating component, at least a part of which is located between the first connecting section and the third connecting section.