Rechargeable Battery Top Plate Triangular Welding
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Solution Overview
Problem
Existing rechargeable battery designs face challenges in securing a balance between maintaining a high adhesive force between the top plate and cap plate while ensuring sufficient space for coupling the lead plate, which affects the hermetic sealing and electrical connectivity.
Innovation Solution
The rechargeable battery incorporates a top plate with strategically arranged welding points forming triangular shapes, allowing for increased adhesive force between the top plate and cap plate while maximizing the area for the lead plate attachment, utilizing materials like nickel or nickel alloys for welding units and aluminum or aluminum alloys for the cap plate, and employing ultrasonic welding for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the top plate is coupled to the cap plate with multiple welding points to increase adhesive force, then the bonding strength is improved, but the space available for lead plate attachment is reduced
Solution Approach 1:
The welding points are segmented into two distinct groups: a first group of welding points (first through third welding points) arranged in a triangular shape for coupling the top plate to the cap plate, and a second group of welding points (fourth through sixth welding points) arranged in another triangular shape for attaching the lead plate. This segmentation allows each group to independently fulfill its function without interfering with the other, thereby resolving the contradiction between maximizing bonding strength and preserving attachment space.
Solution Approach 2:
The welding points are arranged in three-dimensional space with specific spatial relationships. The first group of welding points is positioned at a first distance from a reference line, while the second group is positioned at a second distance from the same reference line. This dimensional arrangement in space allows both groups of welding points to coexist without overlapping, enabling both the top plate-cop plate coupling and lead plate attachment to occur simultaneously with sufficient space for both functions.
2Reliability
If the welding points are arranged to maximize adhesive force, then the hermetic sealing is improved, but the electrical connectivity space is reduced
Solution Approach 1:
The welding points are segmented into functionally distinct groups: the first group (first through third welding points) is dedicated to hermetic sealing by coupling the top plate to the cap plate, while the second group (fourth through sixth welding points) is dedicated to electrical connectivity by attaching the lead plate. This functional segmentation ensures that each welding group optimizes its specific purpose without compromising the other, thereby resolving the contradiction between hermetic sealing and electrical connectivity space.
Solution Approach 2:
The two groups of welding points are positioned at different distances from a reference line, creating spatial separation in the third dimension. The first group is located at a first distance while the second group is located at a second distance, allowing both hermetic sealing and electrical connectivity functions to be simultaneously achieved with adequate space allocation for each function.
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 configuration enhances the adhesive force between the top plate and cap plate, ensures a sufficient space for lead plate attachment, and maintains a hermetically sealed state, thereby improving the overall performance and reliability of the rechargeable battery.
Implementation Method 1
employing ultrasonic welding for secure connections
Data Source
AI summary
A rechargeable battery includes an electrode assembly including a first electrode plate, a second electrode plate, and a separator between the first electrode plate and the second electrode plate, a can in which the electrode assembly is accommodated, the can including an opening at one side, the opening being hermetically sealed by a cap plate, and a top plate on the cap plate. The top plate includes a first welding unit and a second welding unit that are coupled to the cap plate, and a third welding unit that is between the first welding unit and the second welding unit. The first welding unit is connected to the cap plate and includes first through third welding points. The first through third welding points collectively forming a triangular shape.