Button Battery Lid Adapter Structure for Hermetic Sealing
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Solution Overview
Problem
Existing button battery designs face challenges in manufacturing due to the need for precise dimensions and accurate alignment of the lid and cup for a perfect weld, which can lead to imperfect seals and potential leakage.
Innovation Solution
The battery design incorporates a lid with an inner electrically conductive portion, an intermediate insulating portion, and a peripheral adapter portion that can be adapted to various cup shapes and sizes, allowing for a universal fit and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to fix the lid to the cup rim, then a hermetic seal can be achieved, but the manufacturing precision requirements increase significantly
Solution Approach 1:
The lid is divided into three distinct portions: an electrically conductive central portion, an electrically conductive peripheral portion, and an electrically insulating intermediate portion. This segmentation allows each portion to serve its specific function while reducing the overall dimensional constraints on the welding process, as the modular structure provides tolerance for alignment variations.
Solution Approach 2:
The electrically insulating intermediate portion acts as a mediator between the two electrically conductive portions. This intermediate layer provides a buffer zone that accommodates dimensional variations and alignment tolerances, reducing the stringency of manufacturing precision requirements while maintaining effective sealing through the peripheral portion's connection to the cup rim.
2Reliability
If the lid dimensions are precisely matched to the cup rim, then a perfect weld seal is achieved, but the device complexity increases
Solution Approach 1:
The lid design with its standardized three-portion structure can be adapted to various cup sizes and shapes, providing a universal solution that reduces complexity. The modular portions can be configured to fit different battery dimensions while maintaining the same fundamental sealing mechanism, eliminating the need for custom-designed lids for each cup variant.
3Reliability
If the lid is precisely positioned during welding, then sealing integrity is maintained, but the ease of manufacture decreases
Solution Approach 1:
By dividing the lid into separate functional portions, the assembly process becomes more straightforward. The electrically insulating intermediate portion can be positioned independently to provide electrical isolation, while the peripheral portion is optimized for the welding connection to the cup rim, simplifying the overall positioning requirements during manufacturing.
Data Source
Figure 1
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AI summary
In one aspect the present invention concerns a battery (30) comprising: - a cup-shaped bottom container (1) to accommodate an electrode assembly (4), the bottom container (1) comprising a base (2) and an upstanding sidewall (3) along an outer circumference of the base (2), - a lid (10) comprising: o an inner electrically conductive portion (11), o an intermediate insulating portion (13) surrounding the inner electrically conductive portion (11), and o a peripheral adapter portion (12, 15) forming or constituting an outer peripheral edge portion (26) of the lid (10) and fixable to the sidewall (3) of the bottom container (1) via the outer peripheral edge portion (26), wherein the peripheral adapter portion (12, 15) is sized, shaped and/or configured to bridge a gap between an outer edge (28) of the intermediate portion (13) and an inside perimeter of the sidewall (3).