Battery Can Steel Plate Diffusion Layers for Leak Resistance and Discharge
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Solution Overview
Problem
Existing steel plates for battery cans face challenges in achieving both improved leakage resistance and heavy load discharge performance, as increasing the exposure of iron to enhance discharge performance compromises leakage resistance.
Innovation Solution
A method for producing a steel plate for battery cans involves forming a steel plate with a specific structure that includes an outer peripheral side plated layer, an outer peripheral side diffusion layer, a base material steel plate, an inner peripheral side diffusion layer, and an inner peripheral side plated layer. The inner peripheral side plated layer and diffusion layer are formed through heat diffusion treatment, optimizing the thickness and composition to balance leakage resistance and discharge performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plated layer is thickened to improve leakage resistance, then leakage resistance is improved, but heavy load discharge performance deteriorates
Solution Approach 1:
The patent applies local quality by creating different plated layer structures at different locations. The inner peripheral side has a first plated layer with specific Fe concentration (10-70 atomic%) for leakage resistance, while the outer peripheral side has a second plated layer with different Fe concentration for discharge performance. This spatial differentiation of material properties resolves the contradiction between leakage resistance and discharge performance.
Solution Approach 2:
The patent uses composite materials by combining multiple plated layers with different compositions and structures. The steel plate comprises a base material steel plate with an inner peripheral side plated layer and an outer peripheral side plated layer, each having different Fe concentrations and microstructures. This composite structure allows simultaneous optimization of leakage resistance (inner layer) and heavy load discharge performance (outer layer).
2Reliability
If the average diameter of crystal grains is decreased to improve leakage resistance, then leakage resistance is improved, but heavy load discharge performance deteriorates
Solution Approach 1:
The patent applies local quality by controlling crystal grain size differently at different locations. The inner peripheral side plated layer has a first average crystal grain diameter optimized for leakage resistance, while the outer peripheral side plated layer has a second average crystal grain diameter optimized for discharge performance. This localized control of microstructural parameters resolves the contradiction.
3Power
If the inner surface is made rough to expose iron and reduce contact resistance, then heavy load discharge performance is improved, but leakage resistance deteriorates
Solution Approach 1:
The patent applies local quality by creating different surface roughness characteristics at different locations. The outer peripheral side plated layer has a surface with specific roughness (Ra value) that exposes iron for reduced contact resistance and improved discharge performance, while the inner peripheral side plated layer has different surface characteristics for maintaining leakage resistance. This spatial differentiation resolves the contradiction between discharge performance and leakage resistance.
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 proposed method achieves an alkaline battery with superior leakage resistance and heavy load discharge performance by controlling the average number of crystal grains and the thickness of the inner peripheral side plated layers, ensuring both properties are improved simultaneously.
Implementation Method 1
The inner peripheral side plated layer and diffusion layer are formed through heat diffusion treatment, optimizing the thickness and composition to balance leakage resistance and discharge performance
Data Source
Figure 1
Figure 2~3
AI summary
As a battery can forming steel plate 100 that configures an electrode can (a positive electrode can 11) of an alkaline battery 1 and is to be formed into a battery can by presswork, the steel plate as a base material includes an iron and nickel diffusion layer or an iron and nickel-cobalt alloy diffusion layer that is formed by forming a nickel plated layer or a nickel-cobalt alloy plated layer with a thickness of 0.5 to 2.0 µm on an inner surface of a battery can of a steel plate (base material steel plate 102) as a base material, and subsequently performing heat diffusion treatment on the nickel plated layer or the nickel-cobalt alloy plated layer. An average number of crystal grains per 0.25 mm2 unit area of the steel plate as the base material is equal to or more than 12.3.