End Cover Isolation Member Alignment for Battery Terminal Assembly
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Solution Overview
Problem
The assembly efficiency of energy-storage devices is low due to gaps between the terminal post and the isolation sheet, leading to dislocation of the isolation sheet and increased costs.
Innovation Solution
An end cover assembly with an isolation member featuring first and second protrusion portions with elongated protrusions, which fit into blind holes on the conductive block and top cover, respectively, to guide alignment and prevent rotation, thereby ensuring proper positioning and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal post is inserted into the through hole of the isolation sheet without positioning features, then the assembly process is simple, but the isolation sheet is prone to dislocation and manual adjustment is needed
Solution Approach 1:
The isolation sheet is designed with protrusion portions that automatically engage with recessed portions on the conductive block and top cover during assembly. This self-positioning mechanism eliminates the need for manual adjustment and ensures proper alignment without requiring additional positioning operations, thereby improving assembly efficiency while maintaining simplicity
Solution Approach 2:
The protrusion portions on the isolation sheet act as intermediary positioning elements between the terminal post assembly and the housing. These protrusions fit into corresponding recessed portions on the conductive block and top cover, serving as mechanical guides that prevent dislocation and ensure accurate positioning during the assembly process
2Adaptability or versatility
If the through hole is made bigger to accommodate dimensional variations, then the assembly is more tolerant, but the gap between the terminal post and isolation sheet increases causing dislocation
Solution Approach 1:
The solution moves from relying solely on the dimensional fit of the terminal post in the through hole (one-dimensional fitting) to using protrusion portions extending from the isolation sheet that engage with recessed portions on multiple components (multi-dimensional positioning). This additional positioning dimension ensures accurate placement regardless of through hole size variations
Solution Approach 2:
The protrusion portions are pre-formed on the isolation sheet during its manufacturing process. These protrusions serve as preliminary positioning features that guide the isolation sheet into correct alignment with the conductive block and top cover before final assembly, compensating for any dimensional variations in the through hole
Data Source
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AI summary
Disclosed are an end cover assembly, an energy-storage device, and an electricity-consumption device. The end cover assembly that is applicable to the energy-storage device includes an isolation member. A main body of the isolation member has a first surface and a second surface opposite the first surface, and the isolation member defines a first through hole penetrating through both the first surface and the second surface. Multiple first protrusion portions are positioned on the first surface. Each first protrusion portion is spaced apart from the first through hole and provided with at least one first elongated protrusion on an outer peripheral wall of each first protrusion portion. Multiple second protrusion portions are positioned on the second surface. Each second protrusion portion is spaced apart from the first through hole and provided with at least one second elongated protrusion on an outer peripheral wall of each second protrusion portion. A conductive block defines multiple first blind holes on a surface of the conductive block close to the first surface and an assembly hole, and each first blind hole fits one first protrusion portion. A top cover defines multiple second blind holes on a surface of the top cover close to the second surface and a mounting hole, and each second blind hole fits one second protrusion portion. A terminal post includes a post body. The post body passes through the mounting hole, the first through hole, and the assembly hole sequentially, and is fixedly connected to a surface of the conductive block away from the first surface. Each first protrusion portion is inserted in one first blind hole, and each second protrusion portion is inserted in one second blind hole.