Battery Top Cover Welding Stress Relief via Gap Filling
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Solution Overview
Problem
Existing battery top covers face a high probability of cracking during the welding process due to unresolved stress, which increases processing costs and complexity with the need for a groove design on the sealing pin.
Innovation Solution
A top cover design featuring a liquid injection hole with a parallel side face and a sealing pin having a gap, where the welding part connects and fills the gap to release stress, eliminating the need for a groove design and reducing cracking risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a groove design is added on the surface of the sealing pin to release stress, then the cracking risk is reduced, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention extracts the stress release function from the sealing pin surface (by removing the groove design) and relocates it to the welding part structure. The welding part is designed with a specific geometry that inherently provides stress release during the welding process, thereby maintaining reliability while simplifying the sealing pin manufacturing.
Solution Approach 2:
The welding part serves as an intermediary element between the sealing pin and the liquid injection hole. It absorbs and releases welding stress through its own structural design (with a thickness of 0.5-2mm), preventing stress concentration at the sealing pin and eliminating the need for groove designs on the sealing pin surface.
2Reliability
If a groove design is added on the sealing pin surface, then stress can be released during welding, but the working hours and production efficiency decrease
Solution Approach 1:
The stress release function is extracted from the sealing pin manufacturing process and transferred to the welding part design. This eliminates the additional machining steps required for groove creation on the sealing pin, thereby maintaining stress release capability while improving production efficiency.
Solution Approach 2:
The welding part is pre-designed with optimal thickness (0.5-2mm) and geometry to provide inherent stress release capability during welding. This preliminary design consideration eliminates the need for subsequent groove machining operations, streamlining the manufacturing process and improving productivity.
3Reliability
If the first side face is made parallel to the second side face with a gap, then stress is evenly distributed during welding, but the manufacturing precision requirements increase
Solution Approach 1:
The invention changes the geometric parameters of the welding part, specifically setting its thickness between 0.5-2mm. This parameter optimization allows the welding part to effectively distribute stress during welding while accommodating reasonable manufacturing tolerances for the parallelism between the first and second side faces, balancing reliability and manufacturability.
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 design effectively reduces the risk of cracking during welding by evenly distributing stress and simplifying the manufacturing process, thereby lowering costs and enhancing the reliability of the sealing process.
Implementation Method 1
a welding part connecting the sealing pin and the top cover body, and filling at least part of the gap
Data Source
AI summary
The present disclosure relates to a top cover for a battery which belongs to the technical field of batteries, comprising: a top cover body; a liquid injection hole formed in the top cover body and having a first side face; a sealing pin accommodated in the liquid injection hole and having a second side face, wherein the first side face is parallel to the second side face, there exists a gap between the first side face and the second side face; and a welding part connecting the sealing pin and the top cover body, and filling at least part of the gap.