Battery Swaged Joint Structure for Vibration-Resistant Connections
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Solution Overview
Problem
Existing battery manufacturing methods, such as laser welding and swaging with a simple round-shaped die, result in low connection strength and vulnerability to mechanical vibrations or impacts, particularly in batteries used in mobile units.
Innovation Solution
A battery manufacturing method using a swaging device with a die having multiple movable parts and a punch to form a swaged joint with multiple interlock parts, ensuring a stronger connection by allowing the first metallic plate to plastically deform and bite into the metal foil lamination part, enhancing the interlock strength and preventing foreign matter generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spot welding is performed a plurality of 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 a seating part. This mechanical substitution eliminates the need for repeated spot welding operations, preventing metal foil edge rupture and foreign matter generation while achieving reliable mechanical interlocking between the collector sheet and metal foil lamination part.
Solution Approach 2:
The patent changes the fundamental joining mechanism from thermal welding to cold plastic deformation. By using a die with a specifically designed seating part that creates mechanical interlocking through swaging, the process achieves reliable connections without the harmful effects of laser welding, such as repeated mechanical vibrations causing edge rupture.
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 tensile force
Solution Approach 1:
The patent applies local quality by designing a die with a seating part that creates localized mechanical interlocking features. The seating part is positioned to engage specifically with the metal foil lamination part, creating concentrated interlock points that provide high connection strength without requiring complex overall die structures. This localized engagement ensures resistance to tensile forces while maintaining device simplicity.
Solution Approach 2:
The patent introduces a movable part in the die that can move in the radial direction. This dynamic element allows the die to adapt during the swaging process, enabling the formation of effective mechanical interlocks between the collector sheet and metal foil lamination part. The movable part enhances connection strength by creating proper deformation patterns without requiring a completely complex die structure.
3Ease of manufacture
If the metal foil lamination part is sandwiched between collector sheet and backing plate with simple swaging, then manufacturing is simplified, but interlock shallowing causes disjoining under vibration or impact
Solution Approach 1:
The patent uses a die with a seating part that creates localized mechanical interlocking at the critical interface between the collector sheet and metal foil lamination part. This localized engagement ensures that the connection can withstand external vibrations and impacts, improving reliability without complicating the overall manufacturing process. The seating part is specifically positioned to maximize interlock effectiveness.
Solution Approach 2:
The patent incorporates a movable part in the die that enhances the swaging process. This movable element allows for dynamic adjustment during deformation, creating more effective mechanical interlocks that can withstand external forces such as vibration and impact. The dynamic feature maintains ease of manufacture while significantly improving connection stability.
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 conduction reliability and maintains stable conductive connections under external stress, such as vibrations or impacts, while preventing foreign matter generation, resulting in a battery with increased strength and reliability.
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
AI summary
A method for manufacturing a battery herein disclosed includes the steps of: preparing a swaging device including a die having a seating part, a plurality of fixing parts dividedly arranged on the outer circumferential side in the radial direction of the seating part, and a plurality of movable parts respectively arranged between the plurality of fixing parts, and movable toward the outer circumferential side in the radial direction, and a punch to be press-fitted to the seating part of the die; and stacking the first metallic plate, the metal foil lamination part and the second metallic plat on the die, press-fitting the punch to the seating part of the die, and respectively moving the plurality of movable parts toward the outer circumferential side in the radial direction.