Battery Cap-Up Structure for Uniform Electroplating Gaps
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Solution Overview
Problem
The existing electroplating process for rechargeable battery cap-ups often results in plating defects due to insufficient gaps between stacked cap-ups, leading to corrosion and poor welding quality between the cap-up and safety vent.
Innovation Solution
The cap-up design includes a protruding portion with an arc shape that extends outward from the terminal portion, creating a gap between stacked cap-ups during electroplating, allowing for uniform plating solution penetration and preventing plating defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cap-ups are stacked closely together during electroplating to increase production efficiency, then productivity improves, but plating defects occur due to insufficient gap for plating solution penetration
Solution Approach 1:
The terminal portion is segmented into multiple regions including a protruding portion that extends radially outward. This segmentation creates natural spacing zones that allow plating solution to penetrate between stacked cap-ups while maintaining structural integrity and electrical functionality.
Solution Approach 2:
The protruding portion acts as an intermediary element between adjacent cap-ups in the stack. It creates a physical gap that mediates the flow of plating solution, ensuring adequate penetration without requiring excessive spacing that would reduce production efficiency.
2Manufacturing precision
If cap-ups are stacked with sufficient gap to ensure complete plating solution penetration, then plating quality improves, but productivity decreases due to reduced stacking density
Solution Approach 1:
The protruding portion is located specifically at certain regions of the terminal portion where gap creation is most critical for plating solution penetration. This localized feature provides sufficient spacing where needed while maintaining close stacking elsewhere, optimizing both plating quality and productivity.
3Manufacturing precision
If the protruding portion extends too far outward to create adequate gaps, then plating solution penetration improves, but the cap-up structure becomes more complex and welding quality may deteriorate
Solution Approach 1:
The protruding portion has a curved outer surface that smoothly connects to the terminal portion. This curved geometry creates effective spacing for plating solution penetration while maintaining structural simplicity and avoiding sharp edges that could compromise welding quality or excessive complexity in the cap-up design.
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 effectively reduces plating defects, minimizes corrosion, and enhances welding quality between the cap-up and safety vent, ensuring stable current flow and improved manufacturing consistency.
Implementation Method 1
the coating layer may be produced by electroplating. During electroplating, a plurality of cap-ups may be stacked on top of each other and placed into an electrolytic bath
Data Source
AI summary
A rechargeable battery includes an electrode assembly, a can accommodating the electrode assembly in an interior space, and a cap assembly coupled to the can to seal the can. The cap assembly includes a cap-up configured to contact an external device. The cap-up includes a base portion, a through-hole at a center of the base portion, a terminal portion located farther from the electrode assembly than the base portion, and a number of support portions connecting the base portion to the terminal portion. The terminal portion includes a protruding portion extending outward from an edge located between adjacent support portions.