Battery Cell End-Cover Welding for Single-Step Pack Assembly
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Solution Overview
Problem
The complex assembly process of single-cell batteries due to the need for two separate welding processes, one between the negative current collector plate and the housing or end cover, and another between the end cover and the housing, increases manufacturing complexity and cost.
Innovation Solution
A single-cell battery design where the housing, cell, and current collector plate are arranged such that the housing and end cover are connected to the connecting portion of the current collector plate in a single connection process, eliminating the need for a separate connection between the end cover and the current collector plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate welding processes are used (one between negative current collector plate and housing/end cover, another between end cover and housing), then reliable electrical connection and structural assembly are achieved, but the assembly process becomes complex and manufacturing cost increases
Solution Approach 1:
The patent merges the electrical connection function and structural assembly function into a single integrated component (the end cover that simultaneously connects to both the housing and the current collector plate). This allows one welding process to achieve both the structural assembly and electrical connection, eliminating the need for separate welding steps while maintaining reliability of both functions.
Solution Approach 2:
The end cover is designed as a multi-functional component that serves both as a structural element (sealing the housing) and as an electrical conductor (providing the negative current collector plate connection). By making the end cover universal in function, the patent eliminates the need for separate dedicated components for each function, thereby simplifying the assembly process while maintaining reliable electrical connection.
2Reliability
If two separate welding processes are used, then reliable electrical connection and structural assembly are achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the electrical connection function and structural assembly function into a single integrated component (the end cover that simultaneously connects to both the housing and the current collector plate). This allows one welding process to achieve both the structural assembly and electrical connection, eliminating the need for separate welding steps while maintaining reliability of both functions.
Solution Approach 2:
The end cover is designed as a multi-functional component that serves both as a structural element (sealing the housing) and as an electrical conductor (providing the negative current collector plate connection). By making the end cover universal in function, the patent eliminates the need for separate dedicated components for each function, thereby simplifying the assembly process while maintaining reliable electrical connection.
3Ease of manufacture
If the connecting portion of the current collector plate is made thinner, then manufacturing cost is reduced and assembly is simplified, but structural strength may be compromised
Solution Approach 1:
The current collector plate is designed with non-uniform thickness, featuring a thinner connecting portion for cost-effective assembly and a thicker current collecting portion for reliable electrical connection. The local quality variation optimizes both manufacturing cost and functional performance by allocating material thickness according to specific functional requirements of different regions.
Solution Approach 2:
The connecting portion is pre-designed with optimized thickness and geometry before assembly, allowing it to achieve sufficient structural strength for the application while minimizing material usage. The preliminary design of the connecting portion's dimensions and shape ensures that it can withstand the required loads without requiring excessive material thickness.
Data Source
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AI summary
Provided are a single-cell battery and a battery pack including a plurality of single-cell batteries. The single-cell battery includes a housing, a cell, a current collector plate and an end cover; where the housing is provided with an accommodation cavity and an opening communicating with the accommodation cavity; the housing includes an inner surface enclosing to form the accommodation cavity and an end surface connected to an edge of the inner surface and located at the opening; the cell is arranged in the accommodation cavity; the current collector plate is arranged in the accommodation cavity and includes a current collecting portion and a connecting portion connected with each other; the current collecting portion is electrically connected to the cell, and the connecting portion is connected to the end surface; the end cover seals the opening and is connected to a side of the connecting portion away from the end surface; the housing is welded with the connecting portion and the end cover at the end surface. In the present application, an edge of the housing at the opening, the connecting portion and the end cover are stacked and connected in sequence, and then the three can be welded together through one connection process.