Energy Storage Cell Lead Plate Welding for Clean Internal Joining
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Solution Overview
Problem
Conventional resistance welding methods for connecting the lead plate and base in energy storage cells can result in small particles forming inside the housing, potentially causing short circuits between the anode and cathode, and do not allow for optimal heat dissipation and electrical conductivity.
Innovation Solution
The method involves connecting the lead plate and base of the housing using laser beam welding, which allows for a controlled and improved weld quality, reducing the risk of particle formation and enabling better heat and electrical conductivity, while also allowing for a more compact design that increases the active material capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance welding is used to connect the lead plate and base, then a stable connection can be established, but small particles are generated inside the housing that may cause short circuits
Solution Approach 1:
The patent replaces the mechanical resistance welding process with laser beam welding. The laser beam provides a non-contact, precise energy source that melts and fuses the lead plate to the base without generating particles. This substitution of mechanical welding with optical energy-based welding eliminates particle contamination while maintaining connection reliability.
Solution Approach 2:
The patent changes the welding parameters by using laser beam welding instead of resistance welding. The laser beam allows for controlled energy input, precise temperature control, and localized melting, which prevents particle generation while achieving stable metallurgical bonding between the lead plate and base.
2Reliability
If resistance welding is used to connect the lead plate and base, then the connection can be established, but the heat dissipation and electrical conductivity are suboptimal
Solution Approach 1:
The laser beam welding process creates a deeper and more uniform weld penetration compared to resistance welding. This results in a larger weld seam area and better metallurgical bonding, which improves both heat dissipation pathways and electrical conductivity between the lead plate and base.
Solution Approach 2:
The patent optimizes the weld seam geometry through laser beam parameters, achieving a larger and more uniform weld area. This increased weld seam area provides better thermal and electrical contact, improving energy dissipation efficiency while maintaining connection stability.
3Reliability
If a bar-shaped electrode is used in resistance welding, then sufficient current flow and connection force can be achieved, but the hole in the electrode arrangement must be large enough to accommodate it
Solution Approach 1:
The patent replaces the bar-shaped electrode mechanism with a laser beam delivery system. The laser beam can be focused through a much smaller aperture or directly onto the welding point without requiring a large hole. This eliminates the need for a large central hole in the electrode arrangement, maximizing the space available for active materials.
Solution Approach 2:
The laser beam approaches the welding point from a different spatial configuration, allowing energy delivery through a minimal aperture or from the side. This dimensional change in the energy delivery path eliminates the constraint of requiring a large hole for electrode insertion, thereby maximizing active material volume.
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
Laser beam welding enhances the reliability and efficiency of the connection between the lead plate and base, reducing the risk of short circuits and improving the energy storage cell's performance by allowing for better heat dissipation and electrical conductivity, while enabling a more compact design that increases active material capacity.
Implementation Method 1
connecting the lead plate and the base of the housing by laser beam welding
Implementation Method 2
the laser beam can be directed from the outside onto a lower side of the base of the housing
Data Source
AI summary
A method for producing an energy storage cell is provided. According to the method, a housing having a base, a tapping plate, and a wound electrode assembly are provided. The wound electrode assembly is connected to the tapping plate, and the tapping plate, which is connected to the wound electrode assembly, is arranged in the housing. The tapping plate and the base of the housing are connected to each other via laser beam welding.