Battery Terminal Welding Structure to Block Foreign Object Contact
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Solution Overview
Problem
The welded portion between the internal and external terminals in batteries is prone to contact with foreign objects, leading to reduced electrical resistance and requiring expensive laser welding facilities.
Innovation Solution
A battery structure with an insulation member interposed between the internal and external terminals, where the weld is located on the projecting part of the internal terminal, reducing the likelihood of foreign object contact and using solid-state welding to join the terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welded portion is located at the outer circumferential edge of the swaged portion, then the electrical conduction path is formed, but foreign objects can come in contact with the welded portion reducing conduction quality
Solution Approach 1:
The patent introduces an insulation member as an intermediary element that is interposed between the internal terminal and the battery case component. This insulation member covers the welded portion, preventing foreign objects from contacting it while maintaining the electrical conduction path. The insulation member acts as a protective barrier that mediates between the conductive welded portion and the external environment.
Solution Approach 2:
The patent moves the welded portion from the outer circumferential edge to the inner side of the battery case component by changing the spatial arrangement. The welded portion is now located on the inner circumferential surface of the mounting hole rather than on the outer surface, effectively relocating it to another dimension (from external to internal space) where foreign objects cannot access it.
2Reliability
If laser welding is used to join the internal terminal and external terminal, then the welded portion is formed, but expensive laser welding facilities are required
Solution Approach 1:
The patent replaces expensive laser welding facilities with cheaper solid-state welding equipment. While laser welding provides high-quality welds, the patent demonstrates that solid-state welding can achieve sufficient welded portion quality for battery terminals at lower facility costs. The insulation member provides additional protection, allowing the use of more economical welding technology.
Solution Approach 2:
The patent changes the welding parameters from laser welding (high energy, precise) to solid-state welding (lower energy, simpler equipment). By adjusting the welding method and parameters, and compensating with the insulation member protection, the patent achieves acceptable weld quality with less expensive equipment, thereby reducing facility costs.
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
Maintains high-quality conduction paths while lowering facility costs by using less expensive equipment and minimizing foreign object interference.
Implementation Method 1
joining together the internal terminal and the external terminal by laser welding requires a comparatively expensive facility such as a laser welding machine
Data Source
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AI summary
Abattery manufacturing method includes assembling an internal terminal (15), a gasket (12), a battery case component (11b), an insulator (13), and an external terminal (14) into a state where a cylindrical part (12a) of the gasket (12) is fitted in a mounting hole (11c) of the battery case component (11b), a projecting part (15c) of the internal terminal (15) is fitted in the cylindrical part (12a) of the gasket (12), the insulator (13) is disposed on an outer surface of the battery case component (11b) with the projecting part (15c) fitted in a through-hole (13d), and the external terminal (14) is disposed on top of the insulator (13) so as to lie on the projecting part (15c). The external terminal (14) is pressed against the projecting part (15c) of the internal terminal (15), and the external terminal (14) or the internal terminal (15) is vibrated to thereby weld together the projecting part (15c) and the external terminal (14) in a solid state.