Cylindrical Battery Insulating Sheet for Stable External Tab Welding
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Solution Overview
Problem
Existing methods for assembling cylindrical batteries face issues such as welding slag generation and increased risk of short circuits due to internal electric-resistance welding, and weak or false welds with external laser welding, particularly with thin battery tabs.
Innovation Solution
An insulating sheet for cylindrical batteries featuring an eccentric tab through hole or notch, with a metal sheet integrated into the through hole or blind hole, providing increased weldable thickness and stability during external laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If internal electric-resistance welding is used to assemble the tab with the battery shell, then the welding strength is improved, but welding slag and dust are generated increasing the risk of short circuit
Solution Approach 1:
The harmful welding process is extracted and relocated from the internal battery structure to the external environment. The patent uses external laser welding instead of internal electric-resistance welding, so that welding slag and dust are generated outside the battery core rather than inside, eliminating the short circuit risk while maintaining welding strength.
Solution Approach 2:
The insulating sheet serves as an intermediary component that enables external welding while maintaining internal isolation. It provides a structured pathway (tab through hole) for the tab to reach the external welding zone, allowing the welding process to occur externally without compromising the internal battery structure.
2Object-generated harmful factors
If external laser welding is used to avoid welding slag, then the risk of short circuit is reduced, but the thin tab causes weak or false welds
Solution Approach 1:
The insulating sheet acts as a mediator that supports the thin tab during external laser welding. By providing the tab through hole and structural support, it enables the thin tab to be properly positioned and welded externally without causing weak or false welds, while still avoiding welding slag generation inside the battery.
Solution Approach 2:
The patent changes the welding parameters by using external laser welding instead of internal electric-resistance welding. This parameter change allows welding to occur in an environment where slag can be safely expelled, and the insulating sheet structure compensates for the thin tab's vulnerability by providing proper positioning and support during the welding process.
3Device complexity
If a simple insulating sheet with tab through hole is used, then the manufacturing complexity is reduced, but the weldable thickness of the tab is insufficient
Solution Approach 1:
The patent merges the insulating sheet with the welding support function by integrating the tab through hole structure into the insulating sheet itself. This combination allows the insulating sheet to simultaneously provide electrical isolation and structural support for welding, increasing the effective weldable thickness without significantly increasing manufacturing complexity.
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
The solution enhances weld stability and safety by increasing the thickness of the material to be welded, reducing the risk of false welds and short circuits, and allowing for continuous monitoring during production.
Implementation Method 1
a laser beam of a laser welding equipment irradiates near a center of an outer surface of the end face of the battery shell, and the battery shell is partially melted and welded with the tab to integrate together
Data Source
AI summary
The present application discloses an insulating sheet of a cylindrical battery, including an insulating sheet body. A tab through hole or a tab notch is formed in the insulating sheet body, the tab through hole or the tab notch is arranged to be eccentric. The insulating sheet of the cylindrical battery further includes a blind hole or a through hole formed in a middle portion of the insulating sheet body, and further includes a metal sheet. The metal sheet covers on an opening at an end of the blind hole or the through hole and/or is arranged in the blind hole or the through hole. A surface of the metal sheet protrudes or is flush with the opening of the blind hole or the through hole, and a thickness of the metal sheet in the through hole is smaller than a depth of the through hole.