Battery End Cover Assembly With Step-Shielded Weld Seam
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Solution Overview
Problem
The reliability of end cover assemblies in rechargeable batteries is compromised due to welding heat damage during assembly, leading to partial failures and affecting the overall performance of the battery.
Innovation Solution
The end cover assembly design includes a top cover unit, an upper plastic member, and a fixing member, with a pole penetrating the top cover unit and a connecting portion, where the upper plastic member is partially sleeved on the base portion, and the fixing member is positioned to abut against a step surface, creating a seam that shields the inner sleeve from welding heat, thereby preventing damage and enhancing assembly precision and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If welding is performed during end cover assembly, then assembly is completed and parts are joined, but welding heat damages other parts causing partial failures
Solution Approach 1:
The patent introduces a shielding structure (intermediary element) that positions itself between the welding heat source and the plastic components. This intermediary shields the temperature-sensitive parts from direct heat exposure during the welding process, allowing assembly to proceed without damaging the plastic components while maintaining connection integrity.
Solution Approach 2:
The end cover assembly is divided into distinct functional zones: a welding-resistant metal framework that can withstand high temperatures, and temperature-sensitive plastic components that require protection. This segmentation allows the welding operation to be performed on the metal framework while the plastic components are positioned in protected zones, enabling both joining and component integrity.
2Strength
If welding heat is applied to join parts, then connection strength is achieved, but heat damages temperature-sensitive parts
Solution Approach 1:
A heat-shielding intermediary structure is introduced that absorbs or deflects welding heat away from temperature-sensitive components. This intermediary allows strong welding connections to be formed in the metal framework while preventing heat damage to plastic parts, thus achieving both connection strength and component integrity.
Solution Approach 2:
Different parts of the assembly are designed with different thermal properties: metal components with high heat resistance are positioned in the welding zone where strong connections are needed, while plastic components with low heat resistance are positioned in protected zones. This local differentiation of thermal properties allows welding to proceed without damaging sensitive parts.
Data Source
AI summary
An end cover assembly includes a top cover unit, a pole, an upper plastic member, and a fixing member. The pole penetrates the top cover unit and includes a base portion and a connecting portion protruding from an end surface of the base portion. A part of the end surface of the base portion outside a coverage area of the connecting portion is formed as a step surface surrounding the connecting portion. The upper plastic member is at least partially sleeved on a peripheral side of the base portion. The upper plastic member is partially located at a side of the top cover unit. The fixing member is partially located at the other side of the top cover unit. A seam is formed between the fixing member and the connecting portion and surrounds the connecting portion, and the step surface abuts against the fixing member and cover the seam.