Battery Swaged Joint Structure for Vibration-Resistant Foil Connections
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Solution Overview
Problem
Existing battery manufacturing methods, such as laser welding and simple round-shaped die swaging, result in low connection strength and vulnerability to mechanical vibrations or impacts, leading to potential disjoining of joints and foreign matter generation.
Innovation Solution
A battery manufacturing method using a swaging device with a die having multiple fixing and movable parts, allowing the first metallic plate to radially deform and interlock with the metal foil lamination part, forming a swaged joint with multiple interlock parts for enhanced strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spot welding is performed multiple times with laser to prevent dripping and maintain connection strength, then connection reliability is improved, but mechanical vibration causes metal foil edge rupture and foreign matter generation
Solution Approach 1:
The patent replaces the laser welding process with a swaging process that uses controlled plastic deformation through a die with multiple movable parts. This mechanical swaging process eliminates the need for repeated laser welding, preventing metal foil edge rupture and foreign matter generation while achieving reliable mechanical interlocking between the current collector and terminal
Solution Approach 2:
The die incorporates multiple movable parts that can dynamically adjust during the swaging process. These movable parts allow the die to adapt to the deformation of metal foils in real-time, distributing pressure evenly and preventing edge rupture while achieving adequate interlocking strength in a single operation
2Device complexity
If a simple round-shaped die is used for swaging, then device complexity is reduced, but connection strength is insufficient and disjoining occurs under vibration or impact
Solution Approach 1:
The die is segmented into multiple movable parts that can independently move during the swaging process. This segmentation allows each part to create localized interlocking features with the metal foils, significantly enhancing connection strength and resistance to disjoining under vibration or impact while maintaining reasonable device complexity
Solution Approach 2:
The patent changes the structural parameters of the die by introducing movable parts with varying degrees of freedom. This allows the die to transform from a rigid simple round shape to a dynamically adaptive structure that can create complex interlocking patterns, improving connection strength without excessive complexity
3Ease of manufacture
If the metal foil lamination part is sandwiched between collector sheet and backing plate with simple round die, then ease of manufacture is improved, but interlock shallowing causes low connection strength
Solution Approach 1:
The movable parts of the die can dynamically adjust their positions during the swaging process, allowing the metal foil lamination part to be adequately deformed and interlocked. This dynamic adjustment ensures sufficient interlock depth is achieved while maintaining ease of manufacture through a single-step process
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 method improves connection strength and reliability, preventing foreign matter generation and maintaining stable conductive contact even under external stress like vibrations or impacts, enhancing the battery's performance in applications subject to such forces.
Implementation Method 1
press-fitting the punch to the seating part of the die, and moving the three or more movable parts respectively toward the outer circumferential side in the radial direction, thereby plastically deforming the first metallic plate, the metal foil lamination part, and the second metallic plate
Data Source
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AI summary
A method for manufacturing a battery (10) herein disclosed includes the steps of: preparing a swaging device including a die (110) having a seating part (111), a plurality of fixing parts (112) dividedly arranged on the outer circumferential side in the radial direction of the seating part (111), and a plurality of movable parts (113) respectively arranged between the plurality of fixing parts (112), and movable toward the outer circumferential side in the radial direction, and a punch (120) to be press-fitted to the seating part (111) of the die (110); and stacking the first metallic plate (42, 52), the metal foil lamination part (21, 22) and the second metallic plat (60, 70) on the die (110) , press-fitting the punch (120) to the seating part (111) of the die (110), and respectively moving the plurality of movable parts (113) toward the outer circumferential side in the radial direction.