Battery Cell Conductive Piece Layout Near the Welding Region
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Solution Overview
Problem
Existing battery technologies face issues with micro-cracks at the welding interface between different metal materials, leading to electrolyte leakage and reduced safety and performance over time.
Innovation Solution
A conductive piece is positioned close to the welding region between the end cap and the housing, allowing for molten welding using residual heat from the welding process, eliminating the need for additional welding steps and reducing energy consumption, while forming a conductive cross section to enhance electrical connectivity and prevent micro-cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If penetration welding is performed on the end cap from outside, then the end cap is securely attached to the housing, but micro-cracks occur at the welding interface between different metal materials leading to electrolyte leakage
Solution Approach 1:
The conductive piece serves as an intermediary component positioned between the end cap and the electrode assembly. It is welded to the end cap at a location close to the welding region, acting as a mediator that prevents micro-cracks from forming at the critical welding interface between the end cap and housing, thereby preventing electrolyte leakage while maintaining welding strength.
Solution Approach 2:
The conductive piece is pre-positioned and welded to the end cap before the final assembly is completed. This preliminary welding action creates a protective structure that prevents micro-crack formation in advance, ensuring reliability before the battery enters service.
2Reliability
If an additional welding step is performed to attach the conductive piece to the end cap, then electrical connectivity is ensured, but the manufacturing process becomes more complex and energy consumption increases
Solution Approach 1:
The welding of the conductive piece to the end cap is merged with the existing welding process used to attach the end cap to the housing. By positioning the conductive piece close to the welding region and utilizing the same welding operation, the patent eliminates the need for a separate welding step, thereby simplifying the manufacturing process while ensuring reliable electrical connectivity.
Solution Approach 2:
The welding operation serves multiple functions simultaneously: it attaches the end cap to the housing, provides residual heat for welding the conductive piece, and ensures electrical connectivity. This multi-functionality reduces the number of separate operations required in the manufacturing process.
3Strength
If separate welding steps are used for the end cap and conductive piece, then each component is securely attached, but energy consumption increases due to multiple welding operations
Solution Approach 1:
The welding process continues without interruption to perform multiple functions. The residual heat from welding the end cap to the housing is continuously utilized to weld the conductive piece to the end cap, eliminating the need for a separate heating and welding cycle. This continuous useful action significantly reduces energy consumption while maintaining secure attachment of all components.
Solution Approach 2:
The welding process serves itself by using its own residual heat to complete additional welding tasks. The heat generated from welding the end cap automatically provides the necessary thermal energy for welding the conductive piece, eliminating the need for external energy input for the second welding operation.
4Ease of manufacture
If the conductive piece is positioned far from the welding region, then it is easier to assemble, but the residual heat from welding is insufficient to melt and weld the conductive piece
Solution Approach 1:
The conductive piece is positioned locally close to the welding region, specifically within 15 mm of the welding interface between the end cap and housing. This localized positioning ensures that the piece receives sufficient thermal energy from the residual heat of welding to achieve proper melting and bonding, while still allowing for practical assembly operations.
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 approach improves electrical conductivity, reduces micro-cracks, and enhances the safety and performance of battery cells by preventing electrolyte leakage, thus simplifying the manufacturing process and ensuring reliable electrical connections.
Implementation Method 1
enabling the conductive piece to be molten-welded to the at least one of the end cap and the housing by using the heat from welding
Implementation Method 2
similar to the laser conduction welding and can reduce micro-cracks
Implementation Method 3
residual heat during welding of the end cap and the housing is indirectly used for molten welding of the conductive piece
Implementation Method 4
high temperatures make the atoms of a top metal layer dissolve in each other to form a conductive cross section
Data Source
AI summary
A battery cell includes: a housing, wherein an opening is provided at an end portion of the housing; an electrode assembly arranged inside the housing, the electrode assembly including an electrode body and a first tab, the first tab being leaded from one end of the electrode body; an end cap closing the opening, the outer periphery of the end cap being fixed to the housing by welding; and a conductive piece located between the electrode assembly and the end cap, the conductive piece being electrically connected to the first tab, the conductive piece being electrically connected to at least one of the end cap and the housing, and an outer edge of the conductive piece extending at a position close to a welding region.