Battery Cap Plate With Variable Thickness For Welding Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Batteries face challenges in increasing power capacity without enlarging external dimensions or reducing electrode plate sizes, as the capacity is limited by electrolyte volume and deteriorates over time, and thinning the cap plate for increased volume complicates welding and leads to potential leaks.
Innovation Solution
A battery design with a cap plate having varying thicknesses, including a ribbed structure for increased electrolyte volume and reinforced welding areas to prevent leaks, allowing for efficient electrolyte injection and secure welding without enlarging the battery's external dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the cap plate is thinned to increase internal volume for electrolyte, then the battery capacity is improved, but the welding reliability deteriorates and leaks occur
Solution Approach 1:
The cap plate is designed with non-uniform thickness, featuring a thinner major area (0.3-0.7mm) for increased electrolyte volume and a thicker welded portion (0.8-1.2mm) at the periphery for reliable welding. This local quality variation resolves the contradiction by optimizing each region for its specific function.
Solution Approach 2:
The thickness dimension of the cap plate is varied across different spatial locations rather than maintaining a uniform thickness. This dimensional change allows the cap plate to simultaneously achieve both increased internal volume and sufficient welding material availability.
2Quantity of substance
If the cap plate is thinned to increase internal volume for electrolyte, then the battery capacity is improved, but the manufacturing complexity increases
Solution Approach 1:
The cap plate incorporates a localized thicker welded portion only where needed for welding operations, while the major area remains thin for electrolyte storage. This targeted approach increases electrolyte volume without unnecessarily complicating the overall structure.
3Quantity of substance
If the external dimensions are increased to increase power capacity, then the battery capacity is improved, but the portability deteriorates
Solution Approach 1:
The cap plate's non-uniform thickness design maximizes electrolyte volume within the constrained external dimensions of the battery, allowing increased capacity without increasing the battery's overall size.
Solution Approach 2:
Instead of increasing electrolyte volume by enlarging external dimensions, the invention utilizes the thickness dimension of the cap plate strategically, varying it across the surface to optimize internal volume within fixed external boundaries.
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 enhances internal volume for electrolyte without increasing external dimensions, ensuring reliable welding and reducing electrolyte leakage, thus maintaining battery capacity and performance over time.
Implementation Method 1
a cap plate attached to the case to cover the opening, the cap plate including a welded portion that is thicker than a major area of the cap plate
Data Source
AI summary
A battery including a case defining a cavity for housing an electrode assembly, the case having an opening for receiving the electrode assembly, and a cap plate attached to the case to cover the opening, the cap plate including a welded portion that is thicker than a major area of the cap plate.