Battery Cell Rim Weld Geometry for Misalignment-Tolerant Assembly
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Solution Overview
Problem
Existing battery welding processes for connecting battery cells to current collector assemblies (CCAs) are unreliable and result in high manufacturing waste due to misaligned welds, necessitating complex alignment tools and reduced yield.
Innovation Solution
Implementing wider welds with increased width and depth between the battery cell rim and current collector, which accommodate process variations and simplify assembly by reducing the need for precise alignment tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise alignment tools and complex alignment procedures are used, then manufacturing precision of welds is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the width parameter of the weld from a narrow dimension to a wide dimension (wider than the peripheral rim). This parameter change allows the weld to accommodate misalignment without compromising connection quality, thereby reducing the need for complex alignment tools while maintaining welding precision.
Solution Approach 2:
The asymmetric portion in the gasket serves as a pre-positioned alignment feature that compensates for potential misalignment before welding occurs. By incorporating this cushioning feature in advance, the system tolerates alignment variations without requiring complex alignment procedures during assembly.
2Loss of substance
If narrower welds matching the peripheral rim width are used, then manufacturing waste is reduced, but reliability of welding connections deteriorates due to misalignment sensitivity
Solution Approach 1:
The weld width parameter is increased beyond the peripheral rim width, creating a wider weld that is less sensitive to misalignment. This parameter change improves welding connection reliability by providing a larger tolerance margin, while the asymmetric gasket feature minimizes material waste by ensuring proper positioning.
Solution Approach 2:
The asymmetric portion in the gasket creates a non-symmetric configuration that guides proper alignment during assembly. This asymmetry ensures that the wider weld is positioned correctly relative to the peripheral rim, maintaining connection reliability while accommodating the increased weld width without excessive material waste.
3Manufacturing precision
If complex alignment tools are implemented, then manufacturing precision is improved, but productivity decreases due to extended assembly time
Solution Approach 1:
By increasing the weld width parameter beyond the peripheral rim width, the system achieves adequate alignment tolerance without requiring complex alignment tools or procedures. This parameter change enables faster assembly while maintaining acceptable welding precision, thereby improving productivity.
Solution Approach 2:
The asymmetric portion in the gasket provides self-alignment functionality, allowing the components to find their correct position automatically during assembly without requiring external alignment tools or complex procedures. This self-service alignment feature speeds up the assembly process while maintaining welding precision.
4Reliability
If wider welds are used, then reliability of welding connections is improved by accommodating misalignment, but manufacturing precision requirements increase
Solution Approach 1:
The asymmetric portion in the gasket serves as a positioning feature that guides the weld location relative to the peripheral rim. By incorporating this asymmetric guide, the system achieves reliable welding connections with wider welds while maintaining adequate control over weld placement, reducing the stringency of manufacturing precision requirements.
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
Enhances the reliability and yield of battery module production by minimizing misaligned welds and waste, while simplifying the assembly process.
Implementation Method 1
at least one weld configured to couple the peripheral rim to a connector
Data Source
AI summary
Aspects of the subject disclosure relate to various features of a battery subassembly, such as a battery module. The battery subassembly may be implemented in an electric vehicle or in a building. In one or more implementations, the battery subassembly may include a battery cell having a peripheral rim having a first width and forming a terminal for the battery cell; and at least one weld configured to couple the peripheral rim to a connector, in which the at least one weld has a second width that is larger than the first width.