Battery Welding Heat Shield Structure for Separator-Safe Seam Welding

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Solution Overview

Problem

The challenge of preventing damage to the separator of an electrode assembly during the laser seam welding process of a battery can, which is typically caused by high energy density welding heat, while maintaining the sealing and mechanical strength of the welding portion.

Innovation Solution

Incorporating a welding heat shield member, specifically an insulating member made of high heat-resistant polymer materials like polycarbonate, polyethylene naphthalate, polyether ether ketone, or polyethylene terephthalate, between the current collection plate and the electrode assembly to minimize the impact of welding heat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If high energy density laser is used for seam welding, then welding bead width and penetration depth are improved, but separator damage risk increases

Engineering Contradiction:

Improvewelding bead qualityVSAvoidseparator damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

A heat shield member made of heat-resistant material (such as ceramic coating or metal plate) is positioned between the laser welding zone and the separator to block and dissipate welding heat, preventing thermal damage to the separator while allowing high energy density laser welding to proceed

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heat shield member is pre-installed on the separator or positioned in the welding path before the laser welding process begins, establishing thermal protection in advance to withstand the high energy density laser beam

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If low energy density laser is used to prevent separator damage, then separator safety is improved, but welding bead width and penetration depth decrease

Engineering Contradiction:

Improveseparator damage preventionVSAvoidwelding bead quality

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The heat shield member acts as a thermal barrier that allows the use of higher energy density lasers without directly exposing the separator to harmful heat, thereby maintaining both welding quality and separator safety

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

By introducing the heat shield member, the system can operate with higher laser energy density parameters than would be safe without the shield, effectively changing the thermal parameters in the welding zone while protecting the separator

Inventive Principle:

Principle #35Parameter changes

3Reliability

If high energy density laser is used, then sealing property and mechanical strength are improved, but process window narrows

Engineering Contradiction:

Improvesealing propertyVSAvoidprocess window

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The heat shield member decouples the laser energy density from the thermal exposure of the separator, allowing a broader range of laser parameters to be used safely, thereby expanding the process window for welding optimization

Inventive Principle:

Principle #24Intermediary (Mediator)

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 allows for seam welding with high energy density lasers without damaging the separator, ensuring adequate welding bead width and penetration depth, thereby securing sealing ability and mechanical strength, and expanding the process window for optimized production.

Implementation Method 1

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS20260011832A1Welding Heat Shield Member, Electrode Assembly Damage Prevention Structure Using the Same, and Battery Cell Using the Same

Publication Date: 2026.01.08 LG ENERGY SOLUTION LTD

AI summary

A battery cell having a can including a bottom member and a sidewall member, and a cap covering an opening of the can, and an electrode assembly accommodated inside the can is provided. A current collection plate is connected to an electrode tab provided at an open end of the can located at an axial side of the electrode assembly. The current collection plate includes an electrode tab connection portion that electrically connects to the electrode tab. A can connection portion is provided outside the electrode tab connection portion in a radial direction that electrically connects to the can. A conductive connection portion electrically connects the can connection portion and the electrode tab connection portion. A periphery the sidewall member and the cap are seam-welded along a peripheral direction, and part of an insulating member is interposed between the current collection plate and the electrode assembly in the axial direction.