Battery Container Welding with Material-Shortage Section
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Solution Overview
Problem
The existing manufacturing method for battery containers is prone to faulty welding due to the melting and detachment of projections when the welding energy is high, especially for small projections, leading to unreliable bonding.
Innovation Solution
A battery container design that incorporates a material-shortage section near the welding area, where the case and closing members are welded, with a thick-wall section and a material-shortage section formed to concentrate the welding heat, ensuring the welding area is confined within the thick-wall section, allowing for deeper fusion with reduced energy and preventing faulty welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high welding energy is used to ensure proper fusion, then welding strength is improved, but the projection melts and falls off causing faulty welding
Solution Approach 1:
The patent applies local quality by creating a material-shortage section with reduced material thickness specifically at the projection area near the welding section. This localized modification allows the projection to withstand high welding energy without melting, while the welding section itself maintains sufficient material for proper fusion. The material-shortage section is positioned precisely where needed to prevent projection failure, while not interfering with the welding process in the welding section.
2Reliability
If the projection size is increased to prevent melting, then welding reliability is improved, but the device complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying the material thickness parameter locally at the projection area. Instead of increasing the overall projection size, the invention changes the thickness parameter of the material-shortage section to be smaller than the standard wall thickness. This parameter modification allows the projection to resist melting under high welding energy while maintaining the overall simplicity of the device structure.
3Reliability
If welding energy is reduced to prevent projection melting, then faulty welding is prevented, but fusion depth is insufficient
Solution Approach 1:
The patent applies local quality by creating distinct zones with different material properties: the material-shortage section with reduced thickness near the projection, and the welding section with sufficient material for proper fusion. This localized differentiation allows high welding energy to be applied without melting the projection, while ensuring adequate fusion depth in the welding section. The material-shortage section acts as a heat sink that protects the projection, while the welding section receives full thermal energy for proper fusion.
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 enhances the reliability and sealing properties of the battery container by achieving optimal welding with improved fusion depth and reduced energy consumption, minimizing faulty welds and maintaining structural integrity.
Implementation Method 1
the case member and the closing member being brought into contact with each other and welded in the welding section by irradiating the welding section with a welding beam
Data Source
AI summary
A battery container 10 includes a case member 1, one side of the case member 1 being opened, and a closing member 2 for closing the opening. Further, a material-shortage section 24 is formed near a welding section 13, the case member 1 and the closing member 2 being brought into contact with each other and welded in the welding section 13 by irradiating the welding section 13 with a welding beam. Further, the case member 1 is welded with the closing member 2 so that the welding section 13 reaches the material-shortage section 24. Note that a width of the material-shortage section 24 in a welding beam irradiation direction may be equal to or greater than one third of a fusion depth of the welding section 13.