Stepped Battery Cell Case Welding Across Variable Thickness Regions
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Solution Overview
Problem
Existing battery cell manufacturing processes face challenges in achieving improved welding quality and efficiency, particularly in connecting multiple plates and ensuring consistent thickness and structural integrity of the battery case.
Innovation Solution
A battery cell case design with varying thicknesses and strategically placed welding regions, including step welding regions and a main welding region, is formed by bending a single metal plate and welded using a laser with varying heat inputs, ensuring efficient and precise connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single metal plate is bent and welded to form the battery cell case, then manufacturing efficiency is improved, but welding quality and structural integrity are compromised due to varying thicknesses
Solution Approach 1:
The welding process is divided into multiple distinct regions: step welding regions where the plate thickness transitions, and a main welding region for the final seal. This segmentation allows each region to be optimized independently - step regions use lower heat input to prevent deformation, while the main region uses higher heat input for strong welding, thus resolving the contradiction between efficiency and quality
Solution Approach 2:
Different welding parameters (heat input, speed, power) are applied to different regions of the case based on local thickness requirements. The step welding regions receive customized lower heat input suitable for thinner sections, while the main welding region receives higher heat input appropriate for thicker sections, ensuring optimal welding quality throughout without compromising overall manufacturing efficiency
2Manufacturing precision
If laser welding is used with varying heat inputs for different regions, then welding quality is improved, but manufacturing complexity increases
Solution Approach 1:
The laser welding process dynamically adjusts heat input, power, and speed parameters based on the real-time position and local plate thickness. The system transitions smoothly between different welding modes (step welding with lower heat input and main welding with higher heat input) without manual intervention, managing complexity through automated dynamic control rather than static fixed parameters
Solution Approach 2:
The laser welding system incorporates feedback mechanisms that monitor welding conditions and automatically adjust parameters to maintain optimal welding quality. This feedback control manages the complexity of varying heat inputs by using real-time data to self-regulate the process, reducing the need for manual complexity while maintaining high welding precision
3Strength
If the case has varying thicknesses to accommodate different regions, then structural integrity is improved, but manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The case is pre-formed with the required varying thickness profile through bending before welding. This preliminary shaping action creates the step regions and main welding region geometry in advance, allowing the welding process to simply follow the pre-established path with predetermined parameters, thus maintaining dimensional precision while achieving the structural integrity benefits of varying thickness
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 design enhances welding quality, improves manufacturing efficiency, and ensures improved structural integrity and dimensional precision of the battery cell.
Implementation Method 1
welded using a laser with varying heat inputs
Implementation Method 2
one end of the single plate is in contact and another end of the single plate and welded together
Data Source
AI summary
In an embodiment, a battery cell may include: a case including a first open region, a second open region facing each other, at least one step region connected to at least one of the first open region or the second open region, and a receiving region connected to the at least one step region; and an electrode assembly disposed in the receiving region, and including a positive electrode plate, a negative electrode plate, and a separator; a plurality of cap plates covering the first open region and the second open region; at least one step welding region formed in the at least one step region; and a main welding region connected to the at least one step welding region and formed in the receiving region. The receiving region has a first thickness greater than a second thickness of the at least one step region.