Battery Can-Lid Electrical Connection Without Internal Welding
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Solution Overview
Problem
The challenge in manufacturing electric batteries lies in the difficulty and cost of welding an electrically conductive insert to the inner surface of the hollow container due to limited space, which can lead to high production costs and potential weld detachment compromising the battery's operation.
Innovation Solution
A conductive insert is mechanically connected between the container's upper portion and the lid, eliminating the need for welding inside the container and ensuring electrical continuity through plastic deformation and mechanical union.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect the conductive insert to the inner surface of the hollow container, then electrical continuity is achieved, but the manufacturing complexity and cost increase due to limited space and need for specialized equipment
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical connection system. The conductive insert is connected to the hollow container through a mechanical interface that provides both structural support and electrical continuity, eliminating the need for welding equipment and processes.
Solution Approach 2:
The patent introduces an intermediary mechanical connection structure between the conductive insert and the hollow container. This intermediary element facilitates both the mechanical attachment and electrical contact, serving as a mediator that resolves the conflict between reliable electrical connection and manufacturing simplicity.
2Reliability
If welding is performed inside the hollow container cavity, then electrical contact is established, but production time increases and risk of weld detachment compromising battery operation exists
Solution Approach 1:
The patent implements preliminary action by establishing the mechanical connection between the conductive insert and the hollow container before inserting the electrochemical cell into the battery assembly. This sequence allows the mechanical connection to be formed in an accessible position, avoiding the need for difficult internal welding operations after cell insertion.
3Reliability
If welding is used to ensure stable closure, then electrical continuity is maintained, but the risk of weld filler material detaching and contacting electrodes increases
Solution Approach 1:
The patent eliminates the welding process entirely by using a mechanical connection system. This substitution removes the source of harmful weld filler material that could detach and contaminate the battery interior, while still achieving both stable mechanical closure and reliable electrical continuity through the mechanical interface.
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
This method reduces the need for specialized welding equipment, prevents weld residues from reaching the electrochemical cell, and ensures stable electrical contact without increasing production costs.
Implementation Method 1
ensuring electrical continuity through plastic deformation and mechanical union
Data Source
AI summary
An electric battery comprises a hollow container having a side wall and a bottom wall defining an inner cavity, an upper portion opposite to the bottom wall along an axial direction, an electrochemical cell inserted into the inner cavity of the hollow container, an insert made of electrically conductive material mechanically and electrically connected to an anode of the electrochemical cell, a lid placed to close the hollow container at the upper portion and comprising a peripheral portion. The insert made of electrically conductive material comprises a connection portion interposed between the upper portion of the hollow container and the peripheral portion of the lid and in electrical contact with at least the upper portion of the hollow container. The peripheral portion of the lid is in electrical contact with at least the upper portion of the hollow container.