Cylindrical Battery Pole Terminal Assembly for Space-Saving Laser Fixing
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Solution Overview
Problem
The existing cylindrical battery pole terminal structure occupies a large internal space, poses positioning difficulties during welding, affects electrical performance due to metal debris, and lacks material flexibility.
Innovation Solution
A method involving laser welding an irregular-shaped screw to a current collector plate, integrating a seal gasket, and using a composite nut to clamp and fix a housing, ensuring reliable electrical connections and flexible material selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rivet structure is used to fix the housing to the pole body, then the housing can be securely fixed, but the rivet occupies a large internal space of the cylindrical battery
Solution Approach 1:
The patent replaces the traditional mechanical rivet fixing system with a laser welding system. The laser welding process directly fuses the housing to the pole body without requiring physical rivets, thereby eliminating the space occupation issue while maintaining secure fixation. The laser beam melts and fuses the materials at the joint, creating a strong bond without mechanical fasteners.
2Strength
If the pole body and current collector plate are welded together, then a strong connection is achieved, but positioning difficulty occurs during welding and metal debris is generated affecting electrical performance
Solution Approach 1:
The patent implements preliminary positioning actions before the actual laser welding process. The pole body and current collector plate are pre-positioned and fixed in their correct relative positions using定位 fixtures or clamps. This preliminary positioning ensures that when laser welding begins, the components are already in the correct alignment, eliminating positioning difficulties during the welding process itself and preventing metal debris generation from misalignment.
3Device complexity
If the pole body and housing are integrally combined with a single material, then structural simplicity is achieved, but use flexibility for a pack end is insufficient
Solution Approach 1:
The patent divides the pole terminal structure into separate modular components: the pole body, the housing, and the current collector plate. These segmented components can be manufactured from different materials optimized for their specific functions and can be assembled through laser welding. This segmentation enables flexibility in material selection and assembly configuration for different pack end applications, while the laser welding process maintains structural integrity.
Solution Approach 2:
The patent employs composite material construction where the pole body, housing, and current collector plate can be made from different materials selected based on their specific functional requirements. For example, the pole body might use copper for electrical conductivity, while the housing could use aluminum for lightweight and corrosion resistance. The laser welding process effectively joins these different materials, creating a composite structure that optimizes performance while providing material flexibility for various applications.
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
Reduces structural member costs, enables high-speed assembly, saves internal space, and enhances electrical reliability with flexible material options.
Implementation Method 1
laser welding an irregular-shaped screw at a central position of a current collector plate
Implementation Method 2
laser welding the current collector plate to a tab of a core
Implementation Method 3
welding and fixing a threaded fit between the nut and the irregular-shaped screw from above with laser
Data Source
AI summary
A method for assembling a pole terminal of a cylindrical battery includes the following steps: step 1: laser welding an irregular-shaped screw at a central position of a current collector plate, to form a composite current collector plate; step 2: laser welding the current collector plate to a tab of a core; step 3: covering the current collector plate with an insulating sheet; step 4: covering the insulating sheet and the core with a housing with an opening facing downward, where the irregular-shaped screw extends upward through an irregular-shaped hole to reach an outer side of a top of the housing; step 5: combining a nut and a nut seal gasket to form a composite nut; step 6: rotatably mounting the composite nut on the irregular-shaped screw; and step 7: welding and fixing a threaded fit between the nut and the irregular-shaped screw from above with laser.