Button Battery Lid Structure for Self-Alignment and Leak Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing process of button batteries faces challenges with imperfect weld connections due to the need for precise alignment and small dimensions, leading to potential leakage from the battery's interior, and the double-wall configuration results in wasted space.
Innovation Solution
A button battery design featuring a cup-shaped container and a lid with complementary conical portions for self-alignment and a uniformly conductive lid for improved sealing, allowing for easier assembly and welding, reducing the need for precise dimension matching and minimizing the risk of leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double-wall configuration with gasket or glue is used for sealing, then electrical insulation is achieved, but space is wasted and manufacturing complexity increases
Solution Approach 1:
The patent merges the sealing function and electrical insulation function into a single integrated lid structure. The lid includes a conductive body portion, an insulating intermediate portion, and a conductive seal portion that work together as one component to provide both sealing and electrical insulation, eliminating the need for separate gaskets or glue layers and thus saving internal battery volume.
Solution Approach 2:
The lid is designed as a multi-functional component that simultaneously provides mechanical sealing, electrical insulation, and electrical conduction. The different portions of the lid (conductive body, insulating intermediate, conductive seal) perform multiple functions within a single component structure, reducing the overall number of parts and optimizing space utilization.
2Reliability
If laser welding is used to fix the lid to the cup, then sealing is improved, but manufacturing precision requirements increase and production difficulty increases due to small dimensions
Solution Approach 1:
The lid structure is designed to be self-aligning during the welding process. The integrated design with properly positioned conductive and insulating portions allows the lid to automatically align with the cup during assembly, reducing the need for high-precision external alignment procedures and making the welding process more robust against dimensional variations.
Solution Approach 2:
The lid design incorporates built-in alignment features and tolerance compensation through its multi-port ion structure. The insulating intermediate portion and the geometry of the conductive portions are designed to accommodate small dimensional variations and maintain proper alignment before welding occurs, cushioning against the effects of manufacturing tolerances.
3Reliability
If a physical gasket is used for sealing, then electrical insulation is provided, but the battery requires a double-wall configuration increasing complexity
Solution Approach 1:
The patent combines the gasket's sealing and insulation functions directly into the lid structure. The insulating intermediate portion and conductive seal portion are integrated into the lid body, eliminating the need for a separate physical gasket component and the associated double-wall configuration, thereby reducing structural complexity.
4Reliability
If glue-type insulating seal is used, then sealing is achieved, but production time increases due to drying or curing requirements
Solution Approach 1:
The patent extracts the time-consuming drying or curing step from the sealing process by replacing the glue-type insulating seal with a mechanically integrated lid structure. The lid provides sealing and insulation through its physical structure and material properties rather than through a chemical bonding process that requires time to set, thereby eliminating the production time delay.
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
The solution enhances the sealing quality and reduces the risk of chemical leakage by ensuring accurate alignment and maintaining the lid's position during welding, while also eliminating the need for a double-wall configuration, thus optimizing space usage.
Implementation Method 1
The sidewall of the cup-shaped container and the edge of the lid-shaped second component are shaped so as to comprise complementary conical portions which are in mutual contact in the assembled battery
Implementation Method 2
The fixed connection of the lid to the cup is electrically conductive so that the base of the cup forms the positive contact of the battery
Data Source
AI summary
A button battery includes a first component (1) in the form of a cup-shaped container, an electrode assembly (4) inserted in the container, and a lid-shaped second component (10) fixed along its outer edge to the upper rim of the sidewall (3) of the container. Either the first or the second component comprises three portions: an electrically conductive central portion (11), an electrically conductive peripheral portion (12) and an electrically insulating intermediate portion (13) that separates and insulates the central portion from the peripheral portion.