Battery Terminal Pressure Welding via Electromagnetic Induction
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Solution Overview
Problem
The existing battery manufacturing methods face challenges in increasing the diameter of the internal terminal shaft to reduce electrical resistance while maintaining the strength of the shaft, which complicates the swaging process due to the rivet-like structure required for terminal connection.
Innovation Solution
A battery design that includes an insulator between the case and terminals, with a pressure-welding method using a coil to deform the boss of the external terminal radially inward, bonding it to the internal terminal shaft, allowing for increased shaft diameter and reliable conductivity without the need for additional welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diameter of the shaft of the internal terminal is increased to reduce electrical resistance, then conductivity is improved, but the shaft becomes stronger and more difficult to swage
Solution Approach 1:
The patent replaces the traditional mechanical swaging process with electromagnetic pressure welding. A coil generates a magnetic field that induces eddy currents in the shaft, creating electromagnetic pressure to bond the external terminal to the shaft. This substitution allows the shaft to maintain larger diameter for better conductivity without requiring excessive swaging force, thus resolving the contradiction between conductivity and manufacturability.
Solution Approach 2:
The invention changes the connection method from mechanical deformation (swaging) to electromagnetic bonding (pressure welding). By altering the fundamental parameter of connection mechanism, the system can accommodate larger shaft diameters that would be difficult to swage, while still achieving reliable electrical and mechanical connection.
2Reliability
If the shaft diameter is increased to reduce electrical resistance, then conductivity improves, but the rivet-like structure becomes more complex
Solution Approach 1:
The electromagnetic pressure welding process eliminates the need for complex rivet-like structures with multiple components (swaging jig, battery case positioning, etc.). The coil-based electromagnetic system provides a simpler, more direct connection method that achieves both mechanical bonding and electrical conductivity without additional structural complexity.
3Ease of manufacture
If traditional swaging method is used to connect terminals, then connection is achieved, but additional welding processes are required
Solution Approach 1:
The patent merges the mechanical connection function and electrical welding function into a single electromagnetic pressure welding process. The coil-generated magnetic field simultaneously provides both the bonding force and the electrical connection, eliminating the need for separate swaging and welding operations, thus improving manufacturing productivity.
Solution Approach 2:
The electromagnetic pressure welding system performs multiple functions simultaneously: it provides mechanical bonding between the external terminal and shaft, ensures electrical conductivity through direct metal contact, and creates a sealed connection. This multi-functionality reduces the total number of manufacturing steps required.
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
This approach enables a larger internal terminal shaft diameter for reduced electrical resistance while ensuring reliable conductivity and airtightness between the terminals, facilitating easier attachment of the electrode body and maintaining structural integrity.
Implementation Method 1
a coil 40 and passing a current through the coil 40 so that a radially inward force is exerted on the boss 18b through electromagnetic induction
Implementation Method 2
passing a current through the coil 40 so that a radially inward force is exerted on the boss 18b through electromagnetic induction and eddy currents
Implementation Method 3
The boss 18b is pressure-welded to the shaft 16b
Implementation Method 4
The shaft 16b may have a deformation mark of plastic deformation that axially pulls the shaft 16b toward outside of the case
Data Source
AI summary
A battery includes a case, an internal terminal, an external terminal, and an insulator. The internal terminal includes an internal terminal base and a shaft. The internal terminal base is disposed inside the case, with the insulator interposed between the case and the internal terminal base. The external terminal includes an external terminal base and a boss. The external terminal base is disposed outside the case, with the insulator interposed between the external terminal base and the case. The boss extends from the external terminal base. The boss receives the shaft of the internal terminal therethrough. The boss is pressure-welded to the shaft of the internal terminal.