Rechargeable Battery Cap Plate Protrusion Welding
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Solution Overview
Problem
Rechargeable batteries face challenges in ensuring safe seating of the cap plate within the case and preventing over-insertion due to size tolerances and non-uniform shapes of the case opening, which complicates assembly and weldability.
Innovation Solution
The cap plate is designed with protrusions that fit into complementary grooves in the case, allowing precise positioning and preventing over-insertion, while the protrusions and grooves are dimensioned to ensure homogeneous welding, enhancing weldability and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cap plate is attached to the case without protrusions, then the assembly process is simpler, but the seating precision and prevention of over-insertion are poor
Solution Approach 1:
The cap plate is segmented by adding protrusions that divide the contact interface into multiple discrete points. These protrusions fit into corresponding grooves on the case, creating localized precision seating areas that ensure accurate positioning without requiring the entire interface to be precisely manufactured.
Solution Approach 2:
The protrusions act as intermediary elements between the cap plate and the case. They provide a mechanical interface that mediates the connection, ensuring precise seating and preventing over-insertion through the complementary groove-protrusion geometry.
2Reliability
If the cap plate is attached to the case without protrusions, then the welding process is simpler, but the weldability and welding quality are poor
Solution Approach 1:
The protrusions create localized welding zones with concentrated material distribution. This local quality enhancement ensures homogeneous welding at the critical contact points between the cap plate and case, improving welding quality and reliability while maintaining overall manufacturing feasibility.
3Manufacturing precision
If protrusions are added to the cap plate, then the seating precision and welding quality are improved, but the manufacturing complexity increases
Solution Approach 1:
The protrusions are pre-formed on the cap plate during its manufacturing process, before assembly with the case. This preliminary action integrates the positioning features into the cap plate production, reducing the need for separate machining or adjustment steps during final assembly.
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 design ensures safe and precise seating of the cap plate, improves weldability, and prevents over-insertion, resulting in a stronger and more reliable battery assembly.
Implementation Method 1
the cap plate comprises at least one protrusion, wherein a length of the protrusion is smaller than a wall thickness of the circumferential edge section, the protrusion projecting from one of the lateral sides and parallel to the inner side
Implementation Method 2
the cap plate is welded to the case and that closes the opening... both, the protrusion and the edge section are at least sectionswise fuzed during the welding process for comparable rated
Data Source
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AI summary
The present invention is directed to a rechargeable battery (1) with a battery housing, the battery housing comprising a case (15), in which an electrode assembly (10) is arranged, the case (15) comprising a circumferential edge section that extends around an opening of the case (15), and a cap plate (20) that closes the opening, wherein the clap plate (20) is formed with an inner side facing the electrode assembly (10), an outer side opposite the inner side, and lateral sides between the inner and the outer side. In order to provide a battery, whose cap plate can be better welded to its case, the invention provides that the cap plate (20) comprises at least one protrusion (721-724) that projects from one of the lateral sides parallel to the inner side, wherein a length of the protrusion is (721-724) smaller than a wall thickness (t1) of the circumferential edge section.