Rivet with snap fit joint

Abstract

A battery (100) comprises a housing (102) with a first end (102a) and a second end (102b) located opposite the first end. A jelly roll (103) is positioned within the housing (102). The first end (102a) includes a through hole (104) accommodating a riveted terminal (106). The riveted terminal (106) consists of an upper section (108) located at the first end's (102a) exterior and a lower section (110) positioned at the first end's (102a) interior. The upper section (108) features a central cavity (108a) and two flanges (109a and 109b) extending from its side wall. The lower section (110) includes a sealing flange (116) affixed to the interior surface of the first end (102a) and a lower cavity (118) with a diameter larger than that of the central cavity (108a). The circumferential wall (120) of the lower cavity (118) is an inclined angle from the flanges (109a, 109b).

Description

[0001] RIVET WITH SNAP FIT JOINT

[0002] FIELD OF INVENTION

[0003] Embodiments of the present application relates to battery technology, specifically to the structural and functional design of a riveted terminal assembly used in batteries to enhance interlocking, electrical connectivity, and assembly efficiency. The invention focuses on improving the interface between the riveted terminal and the current collector disc, incorporating features like bent sections, slots for flexibility, increased landing surfaces, and optimized welding areas. These innovations aim to reduce electrical resistance, ensure reliable mechanical connections, and facilitate advanced manufacturing techniques such as ultrasonic welding, making the invention particularly suitable for modem high-performance batteries.

[0004] BACKGROUND OF THE INVENTION

[0005] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently disclosed invention, or that any publication specifically or implicitly referenced is prior art.

[0006] The demand for efficient and reliable cylindrical secondary batteries, particularly in large- format designs, is increasing due to their application in energy storage and electric vehicles. A key step in the assembly of such batteries involves welding the jelly roll subassembly with the rivet assembly of the battery can. The jelly roll, composed of a positive electrode, negative electrode, and separator, is an essential component requiring precise alignment for optimal performance and safety.

[0007] During the welding process, the cathode disc, which connects to the rivet assembly serving as the electrode terminal, is prone to shifts from the central axis. This misalignment adversely affects the welding region, leading to defects in the welded joint. Such defects compromise the structural integrity of the connection, reduce electrical conductivity, and often necessitate the rejection of the affected cells, resulting in significant manufacturing losses.

[0008] The issue is further exacerbated in tab-less battery designs, where the uncoated portions of the jelly roll are slitted to form tabs directly connected to the current collector. In these designs, the upper current collector disc / plate is connected to the rivet assembly to serve as the electrode

[0009] 7 terminal. However, during the welding process, there is a significant risk of the upper current collector moving away from the central axis, affecting the concentricity of the jelly roll and leading to welding defects. Such misalignment not only reduces the manufacturing yield but also jeopardizes the performance and safety of the final battery product.

[0010] A robust solution is needed to address these challenges by ensuring the concentricity of the jelly roll during the welding process and preventing displacement of the current collector disc / plate. This would minimize welding defects, enhance the structural stability of the battery, and improve manufacturing efficiency.

[0011] SUMMARY OF THE INVENTION

[0012] The following presents a simplified summary of the subject matter in order to provide a basic understanding of some of the aspects of subject matter embodiments. This summary is not an extensive overview of the subject matter. It is not intended to identify key / critical elements of the embodiments or to delineate the scope of the subject matter. Its sole purpose to present some concepts of the subject matter in a simplified form as a prelude to the more detailed description that is presented later.

[0013] A battery disclosed herein provides a robust solution to these challenges by ensuring the concentricity of the jelly roll during the welding process and preventing the displacement of the current collector disc / plate. This approach minimizes welding defects, enhances the structural stability of the battery, and significantly improves manufacturing efficiency. The battery includes a housing with a first end and a second end positioned opposite to each other.

[0014] A jelly roll is placed inside the housing. The first end has a through hole where a riveted terminal is positioned. The riveted terminal consists of an upper section forming a first part and a lower section forming a second part. The first part includes a central cavity and two flanges extending from its side wall. The second part has a sealing flange attached to the lower section of the first end and a lower cavity with a larger diameter than the central cavity (108a). The circumferential wall of the lower cavity is inclined at an angle between 80° and 88°.

[0015] In an embodiment, the battery includes a central cavity in the first part of the riveted terminal, with a diameter ranging from 16.5 mm to 18 mm. This precise dimension ensures compatibility and structural integrity. The lower cavity in the second part of the riveted terminal has a diameter between 22 mm and 24 mm. This increased diameter facilitates effective assembly and reliable operation of the battery. The sealing flange of the second part has a width ranging from 0.8 mm to 1 mm. This ensures a secure seal at the lower section of the first end of the housing, contributing to the battery’s overall reliability.

[0016] In an embodiment, the lower cavity of the second part includes a circumferential wall that features slots. The number of slots ranges from four to six, allowing for controlled flexibility and structural adaptability of the riveted terminal. The slots in the circumferential wall of the lower cavity are distributed either evenly or unevenly. Each slot has a width ranging from 1 mm to 3 mm, ensuring optimal flexibility and secure interlocking during assembly. A current collector disc is engaged within the lower cavity of the riveted terminal. The disc includes a central region designed to interlock with the lower cavity and a top surface that provides a landing area to enhance contact with the riveted terminal.

[0017] In an embodiment, the top surface of the current collector disc is coated with nickel using electroless plating or spray coating. This reduces laser reflectivity during welding, improving the efficiency and accuracy of the manufacturing process. The riveted terminal features a circumferential wall with a bent section in the second part to facilitate insertion and locking of the current collector disc. Additionally, the terminal has an increased landing surface on the first part to reduce electrical resistance and improve welding reliability. Slots in the riveted terminal allow it to expand and regain its original shape, enabling secure interlocking with the current collector disc.

[0018] In an embodiment, the first part of the riveted terminal includes a tapered section designed to ensure an optimum opening angle for laser access during mass production. This enhances the assembly’s efficiency and precision. The current collector disc includes a projection positioned near the bent section. This projection enhances the structural strength of the disc and maintains increased stiffness during interlocking with the riveted terminal.

[0019] In an embodiment, a method for assembling the battery involves providing a housing with a first end and a second end, placing a jelly roll within the housing, and forming a through hole at the first end. A riveted terminal, comprising a first part and a second part, is assembled at the through hole. The first part includes a central cavity and two flanges extending from its side wall. The second part includes a sealing flange attached to the lower section of the first end and a lower cavity with an inclined circumferential wall angled between 80° and 88°, forming a secure interface with the housing. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0020] The following drawings are illustrative of particular examples for enabling systems and methods of the present disclosure, are descriptive of some of the methods and mechanism, and are not intended to limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description.

[0021] FIG. 1A shows a front view of the rivet and can of the battery, as an example embodiment of the present disclosure.

[0022] FIG. IB shows a front view of the rivet and current collector disc of the battery in an assembled state, as an example embodiment of the present disclosure.

[0023] FIG. 1C shows a front view of the current collector disc of the battery, as an example embodiment of the present disclosure.

[0024] FIG. ID shows a front view of the rivet of the battery, as an example embodiment of the present disclosure.

[0025] FIG. IE shows a sectional view of the rivet of the battery, as an example embodiment of the present disclosure.

[0026] FIG. 2A shows an assembled cutaway view of the top portion of the battery, as an example embodiment of the present disclosure.

[0027] FIG. 2B shows an assembled cutaway view of the rivet and current collector disc of the battery in an assembled state, as an example embodiment of the present disclosure.

[0028] FIG. 3A shows an assembled view of the rivet and current collector disc of the battery in an assembled condition, as an example embodiment of the present disclosure.

[0029] FIG. 3B shows another assembled view of the top portion of the battery, as an example embodiment of the present disclosure.

[0030] FIG. 3 C shows a top view of the current collector disc of the battery, as an example embodiment of the present disclosure.

[0031] FIG. 3D shows an isometric view of the top portion of the battery, as an example embodiment of the present disclosure. FIG. 4A-1 shows a front view of the rivet and current collector disc of the battery in an assembled manner, as an example embodiment of the present disclosure.

[0032] FIG. 4B-1 shows a front view of the current collector disc of the battery, as an example embodiment of the present disclosure.

[0033] FIG. 4C- 1 shows a top view of the rivet of the battery, as an example embodiment of the present disclosure.

[0034] FIG. 4D-1 shows a top view of the can, rivet gasket, rivet, and current collector disc assembly of the battery, as an example embodiment of the present disclosure.

[0035] FIG. 4A-2 to 4D-2 show isometric views of the FIGS 4A-1 to 4D-1 respectively, as example embodiments of the present disclosure.

[0036] FIG. 5 shows a sectional view of the current collector disc of the battery showing a projection, as an example embodiment of the present disclosure.

[0037] FIG. 6 shows a partial cutaway view of the rivet of the battery showing the taper and the slots, as an example embodiment of the present disclosure.

[0038] FIGS. 7A-7D show perspective views of the rivet of the battery showing the slots (6 slots in FIGS. 7A-7B and 4 slots in FIGS. 7C-7D), as an example embodiment of the present disclosure.

[0039] FIG. 8 shows the manufacturing process of a rivet in three steps, as an example embodiment of the present disclosure.

[0040] Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may represent hardware components of the system. Further, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.

[0041] DETAILED DESCRIPTION OF THE INVENTION

[0042] Exemplary embodiments now will be described. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. The terminology used in the detailed description of the particular exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to like elements.

[0043] It is to be noted, however, that the reference numerals used herein illustrate only typical embodiments of the present subject matter, and are therefore, not to be considered for limiting of its scope, for the subject matter may admit to other equally effective embodiments.

[0044] The specification may refer to “an”, “one” or “some” embodiment(s) in several locations. This does not necessarily imply that each such reference is to the same embodiment(s), or that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.

[0045] As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes”, “comprises”, “including” and / or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include operatively connected or coupled. As used herein, the term “and / or” includes any and all combinations and arrangements of one or more of the associated listed items.

[0046] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0047] Referring to FIGS. 1A-1D, FIGS. 2A-2B and FIGS 3A-3D, FIG. 1A shows a front view of the rivetted terminal (106) and can of the battery (100), FIG. IB shows a front view of the rivetted terminal (106) and current collector disc (124) of the battery (100) in an assembled state, FIG. 1C shows a front view of the current collector disc (124) of the battery (100), FIG. ID shows a front view of the rivetted terminal (106) of the battery (100), FIG. IE shows a sectional view of the rivetted terminal (106) of the battery (100), FIG. 2A shows an assembled cutaway view of the top portion of the battery (100), and FIG. 2B shows an assembled cutaway view of the rivetted terminal (106) and current collector disc (124) of the battery (100) in an assembled state. FIG. 3 A shows an assembled view of the rivetted terminal (106) and current collector disc (124) of the battery (100) in an assembled condition, FIG. 3B shows another assembled view of the top portion of the battery (100), FIG. 3C shows a top view of the current collector disc (124) of the battery (100), and FIG. 3D shows an isometric view of the top portion of the battery (100), as example embodiments of the present disclosure.

[0048] As illustrated in FIGS. 1A-2B, the battery (100) includes a housing (102) with a first end (102a) and a second end (102b) opposite the first end. A jelly roll (103) is placed inside the housing (102). The first end (102a) features a through hole (104) where a riveted terminal (106) is positioned. The riveted terminal (106) consists of a first part (108) at the upper section of the first end (102a) and a second part (110) at the lower section of the first end (102a). The first part (108) includes a central cavity (108a) and two flanges (109a and 109b) extending from its side wall. The second part (110) has a sealing flange (116) attached to the lower section of the first end (102a) and a lower cavity (118) with an increased diameter compared to the central cavity (108a). The circumferential wall (120) of the lower cavity (118) is inclined at an angle between 80° and 88°.

[0049] As described above, the battery (100) configuration enhances mechanical robustness, electrical efficiency, and sealing integrity through its innovative structural design. The housing (102) securely encloses the jelly roll (103), with a specialized first end ( 102a) incorporating a through hole (104) for the riveted terminal (106). This terminal features a two-part structure, with the first part (108) including a central cavity (108a) for efficient electrical contact and flanges (109a, 109b) for stress distribution and mechanical stability. The second part (110) integrates a sealing flange (116) to prevent electrolyte leakage and a lower cavity (118) with an inclined circumferential wall (120) angled between 80° and 88° for optimized sealing and stress management. The increased diameter of the lower cavity accommodates assembly tolerances while ensuring a secure, resilient connection. Together, these features enhance the battery's reliability, operational safety, and longevity. As shown in FIG. IE, the battery (100) features a central cavity (108a) in the first part (108) of the riveted terminal (106) with a diameter ranging from, for example, 16.5 mm to 18 mm.

[0050] This precise dimension ensures compatibility and structural integrity of the terminal. The central cavity (108a) in the first part (108) of the riveted terminal (106), with the above- mentioned diameter range, provides a critical technical effect by ensuring compatibility with standard connectors while maintaining structural integrity. This specific dimensional range optimizes the balance between ease of assembly and secure electrical contact, reducing the risk of deformation or misalignment during operation. Additionally, it enhances the terminal's ability to withstand mechanical stresses and ensures reliable performance under varying operational conditions.

[0051] As shown in FIG. IE, the diameter of the lower cavity (118) in the second part (110) of the riveted terminal (106) is between 22 mm and 24 mm. This increased diameter allows for effective assembly and functionality of the battery (100). The increased diameter accommodates slight manufacturing tolerances, ensuring proper alignment and secure seating of components during assembly. This design also optimizes the structural integrity and sealing performance of the terminal, contributing to the battery's reliability and operational efficiency under varying conditions.

[0052] As shown in FIG. 2A, the sealing flange (116) of the second part (110) has a width ranging from 0.8 mm to 1 mm. This dimension ensures a secure seal at the lower section of the first end (102a) of the housing (102), contributing to the battery's overall reliability. The sealing flange (116) of the second part (110) provides a secure and reliable seal at the lower section of the first end (102a) of the housing (102). This precise width optimizes the sealing performance, preventing electrolyte leakage and ingress of contaminants while maintaining structural integrity. By achieving an effective seal without compromising assembly efficiency or durability, this design enhances the overall reliability, safety, and longevity of the battery (100).

[0053] As shown in FIG. IE, the lower cavity (118) of the second part (110) comprises a circumferential wall (120) that includes slots (122). The number of slots (122) ranges from four to six, allowing for controlled flexibility and structural adaptability of the riveted terminal (106). With reference to this embodiment, FIGS. 7A-7D show perspective views of the rivet of the battery showing the slots (122) (6 slots in FIGS. 7A-7B and 4 slots in FIGS. 7C-7D), as an example embodiment of the present disclosure . The lower cavity ( 118) of the second part (110) provides a controlled flexibility and structural adaptability of the riveted terminal (106). These slots (122) allow the circumferential wall (120) to adapt to slight dimensional variations during assembly, ensuring a secure and uniform fit. This design improves the terminal's ability to maintain mechanical stability and sealing integrity under operational stresses, enhancing the overall durability and performance of the battery (100).

[0054] As shown in FIG. IE and FIGS. 7A-7D, the slots (122) in the circumferential wall (120) of the lower cavity ( 118) are distributed either evenly or unevenly. Each slot ( 122) has a width ranging from 1 mm to 3 mm, ensuring optimal flexibility and secure interlocking during assembly. The slots (122) in the circumferential wall (120) ofthe lower cavity (118) ensure optimal flexibility and secure interlocking during assembly. This specific width range allows the circumferential wall (120) to adapt effectively to tolerances and variations, facilitating a precise and stable fit. The flexibility introduced by the slots (122) enhances the mechanical resilience of the riveted terminal (106), ensuring reliable sealing and structural integrity, thereby improving the overall performance and durability of the battery (100).

[0055] As shown in FIGS. IB, 1C, 2A, and 5, a current collector disc (124) is engaged within the lower cavity (118) of the riveted terminal (106). The current collector disc (124) includes a central region (124a) designed to interlock with the lower cavity (118) and atop surface (126) that provides a landing area to enhance contact with the riveted terminal (106). The central region (124a) of the disc is specifically designed to interlock with the lower cavity (118), ensuring a secure fit and preventing misalignment during assembly. The top surface (126) of the current collector disc (124) serves as a landing area, improving contact with the riveted terminal (106) and optimizing the flow of current between the terminal and the internal components. This design enhances the battery's overall electrical efficiency.

[0056] Referring to FIGS. 4A-1 to 5, FIG. 4A-1 shows a front view of the riveted terminal (106) and current collector disc (124) of the battery (100) in an assembled manner, FIG. 4B-1 shows a front view of the current collector disc (124) of the battery (100), FIG. 4C-1 shows a top view of the riveted terminal (106) of the battery (100), FIG. 4D-1 shows a top view of the can, rivet gasket, riveted terminal (106), and current collector disc (124) assembly of the battery (100), FIG. 4A-2 to 4D-2 show isometric views of the FIGS 4A-1 to 4D-1, FIG. 5 shows a sectional view of the current collector disc (124) of the battery (100) showing a projection, as example embodiments of the present disclosure. As shown in FIGS. 4A-2, 4B-2, and FIG. 5, the top surface (126) of the current collector disc (124) is coated with nickel using electroless plating or spray coating. This coating minimizes laser reflectivity during welding, enhancing the efficiency and accuracy of the manufacturing process. The nickel coating using electroless plating or spray coating, providing a technical effect by minimizing laser reflectivity during welding. This coating enhances the efficiency and accuracy of the manufacturing process by ensuring more precise energy absorption during the welding process, reducing the risk of defects and improving the quality of the welds. By optimizing the welding conditions, the nickel coating contributes to a more reliable and consistent assembly of the riveted terminal (106) and current collector disc (124), ultimately improving the performance and endurance of the battery (100).

[0057] Furthermore, as shown in FIG. 4A-2 and 4B-2, the cuts ( 134) on the current collector disc (124) are strategically designed to facilitate precise positioning and smooth movement along the conveyor line during assembly or processing. These cuts (134) ensure the current collector disc (124) remains securely aligned while minimizing resistance, allowing for seamless transitions between conveyor segments. This design enhances operational efficiency by streamlining the handling and placement of the current collector disc (124), reducing the risk of misalignment or production delays.

[0058] FIG. 6 shows a partial cutaway view of the riveted terminal (106) of the battery (100) showing the taper (132) and the slots (122), as an example embodiment of the present disclosure. As shown in FIG. IE and 6, the riveted terminal (106) features a circumferential wall (120) with a bent section (130) in the second part (110) to facilitate insertion and locking of the current collector disc (124), so that the riveted terminal (106) snap-fits in contact with the current collector disc (124). Additionally, it includes an increased landing surface on the first part (108) to reduce electrical resistance and improve welding reliability. Slots (122) in the riveted terminal (106) allow it to expand and regain its original shape, enabling secure interlocking with the current collector disc (124). The increased landing surface on the first part (108) reduces electrical resistance, improving welding reliability and ensuring a more efficient electrical connection. Additionally, the slots (122) in the riveted terminal (106) allow it to expand and regain its original shape, providing controlled flexibility that ensures a secure interlocking with the current collector disc (124), ultimately enhancing the battery's electrical performance, structural integrity, and manufacturing efficiency.

[0059] As show in FIGS. 6 and IE, the first part (108) of the riveted terminal (106) includes a tapered section (132) to ensure an optimum opening angle for laser access during mass production, enhancing the assembly's efficiency and precision. This design facilitates precise and efficient welding, enhancing the assembly process by allowing better alignment and focus of the laser, reducing the risk of defects. The tapered section (132) improves the overall manufacturing efficiency and precision, contributing to a higher-quality assembly and more reliable electrical connections in the battery (100). As circumferentially positioned, these slots (132) can expand while inserting the current collector disc (124) inside the riveted terminal (106). Also, thickness of the riveted terminal (106) is reduced, which helps for easier expansion. The tapered section (132) on the top of the first part (108) of the riveted terminal (106) ensures an optimal opening angle, facilitating accurate laser access during mass production.

[0060] FIG. 5 shows a sectional view of the current collector disc (124) of the battery (100) showing a projection (128), as an example embodiment of the present disclosure. The current collector disc (124) includes the projection (128) positioned near the bent section (130). This projection (128) enhances the structural strength of the current collector disc (124) and maintains increased stiffness during interlocking with the riveted terminal (106). This projection (128) ensures that high stiffness is maintained during the process of pushing the current collector disc (124) into the riveted terminal (106). The projection (128) is positioned near the bent section (130) to enhance the structural strength and to maintain increased stiffness during interlocking with the riveted terminal (106). This projection (128) reinforces the current collector disc (124), preventing deformation or misalignment under operational stresses, and ensuring a secure and reliable connection. By improving the rigidity and mechanical stability of the current collector disc (124), the projection (128) contributes to the overall strength and performance of the battery (100).

[0061] As shown in FIGS. 2A and 2B, the method for assembling the battery (100) involves providing a housing ( 102) with a first end ( 102a) and a second end ( 102b), placing a j elly roll (103) within the housing (102), and forming a through hole (104) at the first end (102a). A riveted terminal (106), comprising a first part (108) and a second part (110), is assembled at the through hole (104). The first part (108) includes a central cavity and two flanges extending from its side wall. The second part (110) includes a sealing flange (116) connected to the lower section of the first end ( 102a) and a lower cavity (118) with an inclined circumferential wall (120) angled between 80° and 88°, forming a secure interface with the housing (102).

[0062] FIG. 8 shows the manufacturing process of the riveted terminal (106) in three steps, as an example embodiment of the present disclosure. FIG. 8 outlines a manufacturing process for a rivet using machining and crimping. It describes the steps involved: 1. Step 1 : Machined Rivet o The rivet is initially formed through machining, resulting in a cylindrical body with a flat, circular base.

[0063] 2. Step 2: Bending at the Bottom o The bottom portion of the rivet undergoes a bending process to create a catch projection. This step ensures that the rivet can securely hold the components together during assembly.

[0064] 3. Step 3 : Crimping from the Top o The top side of the rivet is crimped. This step finalizes the assembly by securing the rivet in place, ensuring that the components it holds remain firmly fastened.

[0065] The entire process illustrates how the riveted terminal (106) is shaped and secured through machining, bending, and crimping, allowing for effective assembly in mechanical applications.

[0066] In a short summary, the riveted terminal (106) features a bent section ( 130) at the bottom of the second part (110), designed at an angle to facilitate the smooth insertion of the current collector disc (124) into the lower cavity (118) and lock it securely in place. This bent section (130) acts as a holder with a thickness of 0.5 mm, supporting the current collector disc (124) during interlocking.

[0067] To enhance interlocking, the current collector disc (124) has a top surface (126) with an increased landing area, which creates an interference fit with the riveted terminal (106). This ensures a secure mechanical connection and improves electrical conductivity. The updated design increases the contact area between the riveted terminal (106) and the current collector disc (124) from 8 mm to 12 mm, compared to older designs.

[0068] Additionally, slots (122) are provided along the circumference of the bent section (130) in the second part (110) to allow for expansion and to create a catch mechanism. These slots also improve the flexibility of the riveted terminal (106), enabling it to regain its original shape after the current collector disc (124) is inserted. The slots (122) are made along the bottom portion of the riveted terminal (106), so that when the current collector disc (124) is pushed inside the riveted terminal (106), it will be flexible enough to expand and regain the original shape.

[0069] Benefits of the Proposed Design:

[0070] 1. Enhanced interlocking between the riveted terminal (106) and the current collector disc (124) for improved mechanical stability. . Increased landing area on the top surface (126) of the current collector disc (124), reducing electrical resistance and enhancing welding reliability.

[0071] 3. The additional space facilitates the integration of multiple welding lines or terminals between the cathode and the riveted terminal (106), improving electrical performance. 4. The use of copper materials enables ultrasonic welding, further increasing the weld area for better connectivity.

[0072] Current invention has been discussed specifically with full disclosure. However, numerous changes can be made in the detail of structures, combinations, and part arrangement along with technical advancements that will be implemented in near future without changing the scope of the invention.

[0073] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore, contemplated that such modifications can be made without departing from the scope of the present invention as defined.

Claims

CLAIMS:

1. A batery (100) comprising: a housing (102) having: a first end (102a) and a second end (102b) opposite to the first end (102a), a jelly roll (103) disposed within the housing (102); the first end (102a) having athrough hole (104); a riveted terminal (106) disposed at the through hole (104), the riveted terminal (106) comprising: a first part (108) disposed at an upper section of the first end (102a), and a second part (110) disposed at a lower section of the first end (102a), wherein: the first part (108) comprises: a central cavity (108a), and two flanges (109a and 109b) extending from a side wall of the first part (108); the second part (110) comprises: a sealing flange (116) connected to the lower section of the first end (102a), and a lower cavity (118) with an increased diameter relative to the central cavity (108a), wherein circumferential wall (120) of the lower cavity (118) is at an angle inclined with respect to the flanges (109a and 109b).

2. The batery (100) as claimed in claim 1, wherein the diameter of the central cavity (108a) in the first part (108) ranges from 16.5 mm to 18 mm.

3. The batery (100) as claimed in claim 1, wherein the diameter of the lower cavity (118) in the second part (110) ranges from 22 mm to 24 mm.

4. The batery (100) as claimed in claim 1, wherein the sealing flange (116) of the second part (110) has a width ranging from 0.8 mm to 1 mm.

5. The batery (100) as claimed in claim 1, wherein the lower cavity (118) of the second part (110) comprises the circumferential wall (120) with slots (122), and wherein the number of slots (122) range from 4 to 6.

6. The batery (100) as claimed in claim 5, wherein the slots (122) in the circumferential wall (120) are distributed in one of evenly and unevenly, with each slot (122) having a width ranging from 1 mm to 3 mm.

7. The batery (100) as claimed in claim 1, wherein the circumferential wall (120) of the lower cavity (118) is at an inclined angle ranging from 80° to 88° with respect to the flanges (109a and 109b).

8. The batery (100) as claimed in claim 1, comprising a current collector disc (124) engaged within the lower cavity ( 118) of the riveted terminal (106), wherein the current collector disc (124) comprises: a central region (124a) configured to interlock with the riveted terminal’s (106) lower cavity (118), and a top surface (126) comprising a landing area for improved contact with the riveted terminal (106).

9. The batery (100) as claimed in claim 7, wherein the top surface (126) of the current collector disc (124) is coated with nickel using electroless plating or spray coating to reduce laser reflectivity during welding.

10. The batery (100) as claimed in claim 7, wherein the riveted terminal (106) comprises: the circumferential wall (120), which is a bent section (130) in the second part (110) facilitates insertion and locking of the current collector disc (124), an increased landing surface on the first part ( 108) to reduce electrical resistance and enhance welding reliability, and slots that are formed along a botom portion of the riveted terminal (106), wherein the riveted terminal (106) is enabled to be flexible to expand and regain the original shape when the current collector disc ( 124) is pushed inside the riveted terminal (106).

11. The batery (100) as claimed in claim 9, comprising a tapered section (132) in the first part (108) of the riveted terminal (106) for optimum angle of opening for a laser to contact during mass production.

12. The batery (100) as claimed in claim 7, wherein the current collector disc (124) comprising a projection (128) positioned adjacent to the bent section (130), wherein the projection (128) enhances the structural strength of the current collector disc (124), and wherein the projection (128) maintains increased stiffness during the interlocking ofthe current collector disc (124) with the riveted terminal (106).

13. A method for assembling a battery (100), the method comprising: providing a housing ( 102) having a first end ( 102a) and a second end ( 102b) opposite to the first end (102a); disposing a jelly roll (103) within the housing (102); forming a through hole (104) at the first end (102a) ofthe housing (102); assembling a riveted terminal (106) at the through hole (104), the riveted terminal (106) comprising: a first part (108) disposed at an upper section of the first end (102a) of the housing (102), and a second part (110) disposed at a lower section of the first end (102a) of the housing (102); configuring the first part (108) of the riveted terminal (106) to include: a central cavity, and two flanges extending from a side wall of the first part (108); configuring the second part (110) of the riveted terminal (106) to include: a sealing flange (116) connected to the lower section of the first end (102a) of the housing (102), and a lower cavity (118) having an increased diameter relative to a central cavity (108a) ofthe riveted terminal (106); and inclining circumferential wall (120) of the lower cavity (118) at an angle inclined with respect to the flanges (109a and 109b) to form a secure interface with the housing (102).

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