Battery Can Insert Assembly Without Internal Welding

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Solution Overview

Problem

The existing method for assembling electric batteries is challenging due to the difficulty in welding an insert of electrically conductive material to the inner surface of the hollow container, which requires specialized equipment and techniques, and may compromise the battery's integrity if welds detach.

Innovation Solution

A method where the insert of electrically conductive material is shaped to interpose between the free rim of the hollow container and the lid, allowing for a mechanical union that establishes electrical continuity without the need for welding inside the container.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to connect the insert of electrically conductive material to the inner surface of the hollow container, then electrical continuity is achieved, but the complexity of equipment and techniques increases significantly

Engineering Contradiction:

Improveelectrical continuityVSAvoidwelding equipment and techniques

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical connection system. The insert is shaped to engage with the hollow container and lid through mechanical interlocking, eliminating the need for welding equipment and techniques while maintaining electrical continuity through direct physical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The insert of electrically conductive material serves as an intermediary element that mechanically connects the hollow container and lid while simultaneously providing electrical continuity. This single component mediates both the mechanical and electrical functions that would otherwise require separate welding and connection processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If welding is performed inside the hollow container, then electrical connection is established, but the available space for welding is very limited

Engineering Contradiction:

Improveelectrical connectionVSAvoidwelding space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

Instead of performing welding from inside the hollow container (conventional approach), the patent inverts the approach by shaping the insert to engage mechanically from the outside and internally, creating connection points that are accessible from both directions. This allows adequate welding space to be created where needed while maintaining the compact internal structure.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If specialized welding machines and techniques are used to weld inside the hollow container, then adequate welds can be made, but execution time and production costs increase

Engineering Contradiction:

Improveweld qualityVSAvoidexecution time and production cost

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces complex welding operations with simpler mechanical connection operations. The insert is shaped to provide mechanical engagement features that can be assembled using standard mechanical fastening techniques rather than specialized welding, significantly reducing execution time and production costs while maintaining connection reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The insert is pre-shaped with specific geometric features (protrusions, recesses, or interlocking structures) before assembly. This preliminary shaping allows the components to self-align and connect mechanically during assembly, eliminating the need for complex real-time welding operations and reducing production time.

Inventive Principle:

Principle #10Preliminary action

4Device complexity

If the insert is shaped to interpose between the hollow container and lid for mechanical union, then welding complexity is reduced, but the structural design becomes more complex

Engineering Contradiction:

Improvewelding processVSAvoidinsert geometry

Core Design Contradiction:

Device complexityVSShape

Solution Approach 1:

The insert serves multiple functions simultaneously: it provides electrical continuity, mechanical connection, and structural support. By designing the insert with multi-functional geometry that incorporates both electrical conductivity and mechanical engagement features, the patent reduces overall device complexity despite the specialized shape requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250174784A1Method for assembling an electric battery

Publication Date: 2025.05.29 GD SPA

AI summary

A method for assembling an electric battery comprises providing a hollow container having a side wall and a bottom wall defining an inner cavity, providing an upper portion of the hollow container opposite said bottom wall, providing an insert of electrically conductive material comprising a connection portion, providing a lid comprising a peripheral portion, inserting an electrochemical cell into the inner cavity, mechanically and electrically connecting the insert to an anode of said electrochemical cell. It is further provided for placing the connection portion in electrical contact with the upper portion of the hollow container, placing the peripheral portion of the lid in contact with the connection portion, mechanically joining the connection portion, the upper portion of the hollow container and the peripheral portion of the lid and putting the peripheral portion of the lid in electrical contact with the upper portion of the hollow container.