Button Cell Top Cap Assembly for Flush Welding Stability
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Solution Overview
Problem
The existing button-type secondary batteries face issues with unstable welding quality and assembly yield due to a stepped portion between the base plate and the electrode terminal, which can cause warpage and welding defects, and also result in damage to the electrode assembly from welding heat.
Innovation Solution
A top cap assembly is designed with a base plate bent upward from its circumferential area and an electrode terminal with a protrusion seated on the base plate, eliminating the stepped portion and allowing the welding point to ascend, thereby improving welding quality and minimizing electrode assembly damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a stepped portion is formed between the base plate and the electrode terminal, then the electrode terminal can be securely mounted, but welding quality deteriorates and warpage occurs
Solution Approach 1:
The invention transitions from a two-level stepped structure to a flush, coplanar structure where the electrode terminal surface aligns with the base plate surface. This dimensional change eliminates the stepped portion that caused welding defects while maintaining secure mounting through the protrusion-insertion hole mechanism.
2Ease of manufacture
If the stepped portion is present, then the electrode terminal can be positioned, but assembly yield decreases due to welding defects
Solution Approach 1:
The invention replaces the mechanical stepped positioning system with a protrusion-insertion-hole positioning system. The protrusion on the electrode terminal inserts into the insertion hole in the base plate, providing accurate positioning without creating a stepped portion that would interfere with welding and reduce assembly yield.
3Strength
If welding is performed at the stepped portion, then the top cap assembly is secured, but the electrode assembly is damaged by welding heat
Solution Approach 1:
The invention extracts the welding operation from the problematic stepped portion area and relocates it to the flush surface between the base plate and electrode terminal. This separation removes the harmful thermal effects from the electrode assembly while maintaining secure attachment through the improved welding surface.
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 welding quality and assembly yield of the button-type secondary battery, reduces damage to the electrode assembly from welding heat, and ensures the quality and stability of the battery.
Implementation Method 1
A circumferential area of the top cap assembly 30 is coupled to the can body 10 in a seam welding manner
Data Source
AI summary
A button-type secondary battery has a diameter greater than a height thereof. The button type secondary battery includes a can body defining an accommodation space therein and having an opened upper end; an electrode assembly accommodated in the accommodation space of the can body; and a top cap assembly configured to cover the upper end of the can body and coupled to the can body. The top cap assembly includes a base plate having a flat plate shape and bent upward from a circumferential area thereof; an electrode terminal having a flat plate shape to be seated on an upper portion of the base plate, wherein the electrode terminal comprises a protrusion protruding downward from a central area thereof; and an insulating member between the base plate and the electrode terminal.