End Cover Insulation Structure for Battery Thermal Runaway Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The reliability and safety of energy-storage apparatuses are compromised due to uneven thickness and low structural strength of integrated insulating members in end cover assemblies, which can lead to false triggers and thermal runaway from electrode tab fragments.
Innovation Solution
A separated insulating member structure with distinct components and a metal explosion-proof-valve support enhances structural strength and safety by providing uniform thickness, increased airflow channels, and snap-fit connections, preventing electrode tab fragments from directly contacting the metal support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an integrated insulating member structure is used, then the assembly structure is simple, but the thickness is uneven and structural strength is low
Solution Approach 1:
The insulating member is divided into multiple separate members (first insulating member, second insulating member, third insulating member) instead of using a single integrated structure. Each separate member can be independently manufactured with uniform thickness, and they are connected through connecting members to form the complete insulating assembly, thereby resolving the contradiction between structural simplicity and strength.
Solution Approach 2:
The separate insulating members are nested or stacked together with connecting members in between, creating a layered structure where each layer contributes to the overall strength while maintaining manufacturability. The connecting members are positioned between the insulating members to provide additional structural support.
2Ease of manufacture
If an integrated insulating member is used, then manufacturing is simpler, but the thickness uniformity is poor
Solution Approach 1:
By segmenting the insulating member into multiple separate components, each component can be manufactured independently with controlled and uniform thickness. This avoids the difficulty of maintaining uniform thickness throughout a single large integrated piece, while the overall manufacturing process remains straightforward through modular assembly.
3Strength
If the explosion-proof-valve support is metal, then structural strength is high, but electrode tab fragments can directly contact causing thermal runaway
Solution Approach 1:
An insulating member is introduced as an intermediary component between the metal explosion-proof-valve support and the electrode tab fragments. This insulating member prevents direct contact between conductive fragments and the metal support, eliminating the thermal runaway risk while allowing the metal support to maintain its high structural strength for the explosion-proof function.
4Ease of operation
If the insulating member has low strength, then assembly is easier, but reliability of the end cover assembly is affected
Solution Approach 1:
The insulating member is segmented into multiple separate members that can be individually assembled and positioned. This segmentation allows for easier handling and assembly of each component while the collective assembly of all members provides the necessary reliability and structural integrity for the end cover assembly.
Solution Approach 2:
The separate insulating members are assembled in a nested or stacked configuration with connecting members, creating a robust multi-layer structure. This approach facilitates step-by-step assembly while ensuring that each layer contributes to the overall reliability of the assembly.
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
An end cover assembly, an energy-storage apparatus, and an electricity-consumption device are provided in the present disclosure. The end cover assembly includes an end cover, an insulating member, a positive pole, a negative pole, a first connecting member, and a second connecting member. The insulating member and the end cover are stacked in a first direction. The insulating member includes a first separate member, a second separate member, a third separate member, and a fourth separate member. The first separate member is spaced apart from the second separate member in a second direction. In the second direction, the third separate member and the fourth separate member each are between the first separate member and the second separate member. The third separate member, the first separate member, and the second separate member cooperatively define a first accommodating space. The fourth separate member, the first separate member, and the second separate member cooperatively define a second accommodating space. The positive pole penetrates through the third separate member and the end cover. The negative pole penetrates through the fourth separate member and the end cover. The first connecting member is accommodated in the first accommodating space and connected to the positive pole. The second connecting member is accommodated in the second accommodating space and connected to the negative pole.