Terminal Post End Cover Structure for Electrolyte Sealing
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Solution Overview
Problem
Existing end cover assemblies in energy-storage apparatuses suffer from poor sealing performance, leading to electrolyte leakage and corrosion of structural parts, which compromises safety and reliability.
Innovation Solution
The end cover assembly includes a design with a protrusion portion surrounding the mounting hole, a lug protruding from the upper plastic member, and a terminal post configuration that enhances sealing by minimizing gaps and incorporating sealing rings, thereby preventing electrolyte ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional end cover assembly structure is used, then the device complexity is low, but the sealing performance is poor leading to electrolyte leakage
Solution Approach 1:
The end cover assembly is segmented into multiple functional components: end cover, upper plastic member, terminal post, sealing ring, and pressing block. Each component performs a specific function, with the sealing ring divided into first and second sealing rings for different sealing zones, enabling targeted sealing solutions for different leakage paths
Solution Approach 2:
The upper plastic member acts as an intermediary component between the end cover and terminal post, providing both structural support and sealing function. The pressing block serves as a mediator to apply uniform pressure to the sealing rings, ensuring reliable sealing without direct metal-to-metal contact that could compromise sealing
2Reliability
If the end cover assembly structure is simplified, then the manufacturing cost is reduced, but electrolyte corrosion occurs compromising safety
Solution Approach 1:
The upper plastic member is designed as a thin-walled plastic structure that provides both mechanical support and electrochemical corrosion resistance. The plastic material forms a protective barrier against electrolyte ingress, eliminating the need for complex corrosion protection treatments on metal surfaces
Solution Approach 2:
The assembly combines different materials strategically: plastic materials for corrosion-resistant components (upper plastic member, pressing block), metal for structural components (end cover, terminal post), and elastomeric sealing rings. This composite approach leverages the advantages of each material while minimizing their disadvantages
3Reliability
If gaps between components are reduced to improve sealing, then sealing performance improves, but manufacturing precision requirements increase
Solution Approach 1:
The design incorporates built-in compensation mechanisms: the pressing block provides pre-compression to the sealing rings, and the flexible sealing ring materials accommodate dimensional variations. These cushioning elements compensate for manufacturing tolerances and assembly variations, maintaining reliable sealing without requiring ultra-precise manufacturing
Solution Approach 2:
The sealing rings utilize material parameter changes through compression - as the pressing block applies force, the sealing rings deform elastically to fill gaps and create sealing contact. This material parameter change (elastic deformation) allows the sealing interface to adapt to dimensional variations, reducing the impact of manufacturing precision limitations
Data Source
AI summary
An end cover assembly, an energy-storage apparatus, and an electricity-consumption device are provided. The end cover assembly includes an end cover, an upper plastic member, and a terminal post. The end cover has a first surface. The terminal post includes a terminal-post body and a flange connected to one end of the terminal-post body. The end cover further defines a mounting hole. The protrusion portion protruding from the first surface surrounds the mounting hole and has an end surface. The upper plastic member includes an upper-plastic-member body and a lug. The lug protrudes from an edge of a step surface of the upper-plastic-member body away from a center of the upper plastic member. The upper-plastic-member body and the lug cooperatively define a terminal-post through-hole for the terminal post to pass through. A surface of the flange positioned facing towards the terminal-post body abuts against the step surface.