Cylindrical Secondary Cell Flange-Lid Welding for Simpler Assembly
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Solution Overview
Problem
Existing rechargeable batteries face challenges in efficient manufacturing with complex designs and numerous components, necessitating simplified assembly and reduced parts for improved production speed and cost.
Innovation Solution
A cylindrical secondary cell design featuring a cylindrical enclosure with a flat flange section and a lid that abuts and is welded to the enclosure, eliminating beading grooves and incorporating a recessed contact portion for improved electrical contact and manufacturing ease, along with optional features like a current collector disc and vent openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a beading groove is added to the enclosure sidewall to secure the lid, then the lid can be securely attached, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The flat flange section integrates the sealing surface and the attachment surface into a single continuous structure, eliminating the need for separate beading grooves. The lid is attached directly to this flange section through welding, combining multiple functions (sealing, attachment) into one simplified structure.
Solution Approach 2:
The beading groove feature is completely removed from the enclosure sidewall design. Instead of modifying the sidewall with complex grooves, the patent extracts the attachment function to a separate flat flange section that extends from the sidewall, simplifying the main enclosure structure.
2Adaptability or versatility
If multiple separate components are used for the enclosure and lid assembly, then each component can be optimized independently, but the number of parts increases and assembly becomes more complex
Solution Approach 1:
The flat flange section is formed as an integral part of the enclosure sidewall, merging what could be separate components into a unified structure. This reduces the total number of parts while maintaining the ability to optimize the enclosure and lid independently through their respective design features.
3Reliability
If a complex enclosure design with beading grooves is used, then the lid can be securely attached, but the manufacturing time and production cost increase
Solution Approach 1:
The sealing function and the attachment function are merged into the flat flange section, which provides both the sealing surface against the lid and the attachment surface for welding. This eliminates the need for complex beading groove formation steps, reducing manufacturing time while maintaining seal reliability.
4Reliability
If the enclosure sidewall is modified with beading grooves, then the lid attachment is secured, but the manufacturing precision requirements increase
Solution Approach 1:
The complex beading groove features are extracted from the enclosure sidewall design. The flat flange section provides a simple, flat attachment surface that is much easier to manufacture with high precision compared to forming precise beading grooves in the curved sidewall.
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 simplifies assembly, reduces parts, enhances manufacturing efficiency, and improves energy density while ensuring a reliable seal and safety through a weldable joint and venting mechanism.
Implementation Method 1
the radially outermost portion of the lid is configured to abut and match the flat flange section of the cylindrical enclosure, and is welded to said flat flange section
Data Source
AI summary
There is disclosed herein a cylindrical secondary cell (1), comprising a cylindrical enclosure (2) comprising a first enclosure end (2a), a second enclosure end (2b) and an enclosure sidewall (2c) extending between the enclosure ends (2a, 2b), wherein at least one enclosure end (2b) is open. The cell further comprises an electrode roll (20), a lid (10), and a current collector disc arranged between the lid and the electrode roll (20) and in direct electrical contact with the electrode roll (2). The cylindrical enclosure (2) comprises a flat flange section (2f) extending from the enclosure sidewall (2c) at the open enclosure end (2b), and the radially outermost portion of the lid (10) is configured to abut and match the flat flange section of the cylindrical enclosure, and is welded to said flat flange section (2f).