Beaded Cylindrical Battery Cap Assembly Without Welding

The patent extracts and eliminates the welding process from the cap assembly manufacturing sequence. Instead of welding the cap assembly to the can body, the invention uses a mechanical pressing fit where the cap assembly is simply pressed onto the beading part, removing the complex welding operation while maintaining adequate connection strength for the application.

The beading part on the can body serves a dual function: it provides both the mechanical interface for mounting the cap assembly and the structural feature for securing it through pressing. The deformation of the can body into the beading part creates a self-contained mounting feature that eliminates the need for separate welding fixtures or processes.

The welding operation is completely removed from the manufacturing process. The cap assembly is attached through a single pressing operation that takes place inline with other assembly steps, eliminating the time-consuming welding process and associated setup, positioning, and quality inspection requirements.

The can body is segmented with a localized beading part that creates a mechanical interlock feature. This segmentation allows the cap assembly to be mounted independently through pressing, separating the mounting function from the can body forming process and enabling parallel manufacturing operations.

The patent merges the mechanical mounting function and the electrical connection function into a single integrated structure. The cap assembly includes both the mechanical interface with the beading part and the electrical contact with the current collector plate, eliminating the need for separate welding operations to join these components.

The welding process is extracted from the electrical connection assembly. Instead of welding the current collector plate to the cap assembly, the invention uses direct mechanical contact and pressing, removing the welding step while maintaining adequate electrical connection through the pressed interface.

The welding process is removed entirely from the cap assembly attachment sequence. The mechanical pressing fit provides adequate joint strength for the application without requiring the time-intensive welding operation, including fixture setup, heating, cooling, and quality verification.

The invention accepts a lower-strength mechanical pressing joint instead of a high-strength welded joint. This trade-off is acceptable because the battery's operational life and performance requirements can be met with the simpler, faster pressing attachment method, eliminating the need for expensive and time-consuming welding processes.