Battery Cover Plate Boss Structure for Reflection-Safe Laser Welding
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Solution Overview
Problem
Existing battery designs face issues with laser welding, as reflected light can damage terminal assemblies due to gaps between the cover plate and outer casing, leading to product quality problems.
Innovation Solution
A battery design featuring a boss with a groove and a stamped groove on the cover plate, which reduces chamfers and extends the straight line portion, preventing laser reflection and ensuring effective welding and product yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is used to seal the outer casing, then welding efficiency is improved, but gaps between the cover plate and outer casing cause laser reflection that damages the terminal assembly
Solution Approach 1:
The groove structure acts as an intermediary element between the cover plate and outer casing. It modifies the gap geometry to prevent laser reflection while maintaining the welding process. The groove walls create a configuration where reflected laser is directed away from the terminal assembly, thus mediating between the welding requirement and the protection requirement.
Solution Approach 2:
The cover plate is segmented into different functional zones: the groove region for laser reflection control, the boss region for positioning and sealing, and the connecting edge for welding. This segmentation allows each zone to perform its specific function optimally without interfering with other functions.
2Adaptability or versatility
If gaps are provided between the cover plate and outer casing, then assembly tolerance is improved, but laser reflection occurs within the gaps causing product quality problems
Solution Approach 1:
The groove structure creates local quality variation in the gap region. Instead of a uniform gap, the groove provides a specific geometric configuration at the critical location where laser reflection occurs. This local modification maintains overall assembly tolerance while preventing harmful reflection locally.
3Ease of manufacture
If the boss is formed by stamping at the edges of the cover plate, then manufacturing simplicity is improved, but gaps are created that allow laser reflection
Solution Approach 1:
The groove is formed during the stamping process itself, before the welding operation. This preliminary action of creating the groove structure during stamping modifies the boss geometry in advance to prevent laser reflection, without requiring additional manufacturing steps.
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
The design effectively blocks laser reflection, improving welding quality and ensuring product yield by enhancing the contact between the boss and outer casing, thus protecting the terminal assembly.
Implementation Method 1
certain gaps are provided between the side walls and the outer casings due to the bosses formed by stamping at the edges of the cover plates, so that incident laser is easily reflected within the gaps and reach the terminal assemblies inside the outer casings
Data Source
AI summary
A battery and an electronic apparatus are provided. The battery includes an outer casing including an opening and a cover plate closing the opening. A portion of the cover plate adjacent to an edge protrudes toward an inner cavity of the outer casing to form a boss. A side of the boss facing away from the inner cavity of the outer casing includes a groove, and a portion of the cover plate located at a radial outer side of the boss forms a connecting edge. The boss is embedded into the opening, and the connecting edge overlaps an end portion of the outer casing. An inner wall of the groove includes a bottom wall and an outer groove wall surrounding an outer periphery of the bottom wall. A stamped groove is provided at connection between the bottom wall and the outer groove wall.