Battery Cell Top Cover Assembly for Flexible Module Layouts
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Solution Overview
Problem
The need for different integral harness separators due to varying battery cell sizes and arrangements increases research and manufacturing costs, as well as the time required for developing new production lines when battery cell types are updated or rearranged.
Innovation Solution
A battery module design that integrates a separator plate with a top cover plate, allowing for flexible arrangement of battery cells without altering the separator plate structure, using methods like ultrasonic fusion or projection riveting for fixation, and incorporating electrode connecting structures for stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different integral harness separators are designed for varying battery cell sizes and arrangements, then safety isolation is improved, but research and manufacturing costs increase
Solution Approach 1:
The top cover plate is designed with a standardized separator plate structure that can be universally applied to different battery cell types and arrangements. The separator plate includes a top cover plate body, isolation plates, and positioning structures that maintain their function across various battery configurations, eliminating the need to design separate integral harness separators for each battery cell type.
Solution Approach 2:
The separator plate is divided into functional modules: a top cover plate body, multiple isolation plates positioned at different locations, and positioning structures. This segmentation allows each component to perform its specific isolation function while maintaining overall compatibility with different battery arrangements, reducing manufacturing complexity.
2Reliability
If different integral harness separators are designed for varying battery cell arrangements, then safety isolation is improved, but production line development time increases
Solution Approach 1:
The standardized top cover plate design with configurable isolation plates serves multiple battery cell arrangements simultaneously. The same basic structure can accommodate different battery sizes and layouts by adjusting the number and position of isolation plates, significantly reducing production line development time when updating battery configurations.
Solution Approach 2:
The separator plate design allows dynamic configuration of isolation plates to match different battery arrangements. The positioning structures enable flexible placement of isolation plates without requiring complete redesign of the separator plate, allowing rapid adaptation to new battery cell types and arrangements.
3Productivity
If standardized top cover plate with separator plate is used, then manufacturing efficiency is improved, but adaptability to different battery arrangements may be reduced
Solution Approach 1:
The separator plate is segmented into a standardized top cover plate body and configurable isolation plates. This segmentation maintains manufacturing efficiency through standardization while allowing flexibility in isolating different battery cell arrangements by selectively positioning isolation plates.
Solution Approach 2:
Different regions of the top cover plate can be customized with isolation plates positioned according to specific battery arrangements. The standardized body provides consistent manufacturing benefits, while local modifications with isolation plates ensure adaptability to various battery configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances assembly efficiency, reduces production costs, and maintains compatibility with different battery cell arrangements, minimizing the need for new molds and production lines.
Implementation Method 1
using methods like ultrasonic fusion or projection riveting for fixation
Implementation Method 2
using methods like ultrasonic fusion or projection riveting for fixation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A top cover assembly of a battery cell, a battery cell (1), and a battery module. The top cover assembly of the battery cell (1) includes: a separator plate (1) and a top cover assembly (12). The separator plate (11) is provided with sampling channel(s) (111) for accommodating a sampling member. The top cover plate (12) is configured for sealing an electrode assembly (15) of the battery cell (1) into the battery housing (14), where the top cover plate (12) is provided below the separator plate (11), and the separator plate (11) is fixed to the top cover plate (12). Distinctive from prior art, the top cover assembly and the battery cell may be applied in battery modules using different assembly methods, which greatly improves the efficiency of the battery module assembly with strong the adaptability and high the versatility, and effectively reduces the research and manufacturing costs of a battery system.