Split Battery Insulator Assembly for Tab Isolation and Welding Access
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Solution Overview
Problem
In battery production, the tab formed by bending has poor stability, leading to loose connections and potential short circuits due to contact with the battery housing. Additionally, the integrally formed plastic member with a shielding portion obstructs the welding device's access, affecting positioning and welding quality.
Innovation Solution
A battery insulator with a split design comprising a first member with baffles and a second member with a mounting plate, allowing for separate design and production. The mounting plate is movably connected between the baffles, forming an accommodation groove for the tab, which isolates it from the battery housing and allows for unhindered welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integrally formed plastic member with a shielding portion is used to prevent tab contact with housing, then short circuit prevention is improved, but the welding device cannot access the welding position
Solution Approach 1:
The plastic member is divided into a first member and a second member that can move relative to each other. The first member includes a shielding portion for preventing short circuits, while the second member includes a mounting plate for the tab. This segmentation allows the shielding portion to remain when needed while being movable out of the way during welding operations.
2Reliability
If the shielding portion is extended on the plastic member to isolate the tab from housing, then safety is improved, but the structure becomes complex and manufacturing cost increases
Solution Approach 1:
The plastic member is segmented into two members that work together. The first member provides the shielding function while the second member provides the mounting function. This segmentation actually simplifies the design compared to a complex integrally formed piece with multiple extended portions, as each member can be optimized independently for its specific function.
Data Source
AI summary
Provided is a battery insulator, a top cover assembly, and a battery. The battery insulator includes a first member and a second member. The first member includes a first main body, an end of the first main body facing towards the second member is provided with two baffles at intervals. The second member includes a second main body, and an end of the second main body facing towards the first main body is provided with a mounting plate. The mounting plate is provided with a first pole hole in a penetrating manner, the first pole hole is configured to allow a pole of a battery to pass through, the mounting plate is movably disposed between the two baffles, the mounting plate and the two baffles define an accommodation groove, and the accommodation groove is configured to accommodate a tab connected to the cell.