Button Cell Tab Welding Using an Intermediary Metal Sheet
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Solution Overview
Problem
Existing button cell manufacturing processes damage the surface flatness and stability of the pole shell during electrode tab welding, leading to electrolyte leakage and surface bulging due to penetration of welding currents through the pole shell.
Innovation Solution
A method involving a metal sheet where the electrode tabs are first welded to the sheet, and then the sheet is welded to the pole shell using resistance welding with staggered needle electrodes to form multiple welding points inside the pole shell, preventing current penetration and maintaining surface integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resistance welding or laser welding is used to weld the anode tab directly to the anode shell, then the welding strength is improved, but the welding current penetrates through the pole shell, destroying the surface flatness and stability
Solution Approach 1:
A metal sheet is introduced as an intermediary component between the electrode tab and the pole shell. The tab is first welded to the metal sheet, and then the metal sheet is welded to the pole shell. This intermediary structure prevents the welding current from directly penetrating through the pole shell, thereby maintaining surface flatness while achieving strong welding connections.
2Strength
If the welding current is increased to ensure strong welding, then the welding strength is improved, but the current penetrates through the thin tabs and pole shell, causing electrolyte leakage and surface bulging
Solution Approach 1:
The metal sheet serves as a current-distributing intermediary that prevents concentrated welding current from penetrating through the thin tab and pole shell. By providing an additional conductive layer, it disperses the current path and reduces the risk of electrolyte leakage and surface bulging while maintaining welding strength.
Solution Approach 2:
The welding process is segmented into two separate welding operations: first welding the tab to the metal sheet, and then welding the metal sheet to the pole shell. This segmentation distributes the welding current across multiple interfaces rather than concentrating it through a single thin structure, thereby preventing penetration and structural damage.
3Reliability
If multiple welding points are created to enhance connection stability, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
The welding process is divided into two sequential stages with multiple welding points at each stage. First, multiple welding points are created between the tab and metal sheet; then, multiple welding points are created between the metal sheet and pole shell. This segmentation allows for enhanced connection stability while organizing the complexity into manageable, systematic steps.
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 method ensures the surface integrity of the pole shell, reduces the risk of electrolyte leakage, and enhances the connection stability and discharge efficiency by minimizing internal resistance through multiple, evenly distributed welding points.
Implementation Method 1
pressing two resistance-welded needle electrodes respectively onto the metal sheet or the outer surface of the pole shell and keeping the welding positions of the metal sheet and the electrode tab staggered, and then electrifying the needle electrodes, thereby realizing a fixed connection between the pole shell and the metal sheet
Data Source
AI summary
The present disclosure discloses a button cell, and a method for welding electrode tabs to a pole shell of the button cell. The button cell includes the pole shell and an electric core. The pole shell consists of an anode shell and a cathode shell. The button cell further comprises at least one metal sheet. A cathode tab and/or an anode tab of the electric core is/are welded to the metal sheet, and the metal sheet is then welded to the cathode shell and/or the anode shell. The button cell manufactured by the invention has a complete surface, and can avoid phenomena such as electrolyte leakage and surface bulging caused by the rupture of the polar shell.