Cylindrical Battery External Weld Layout for Debris-Free Assembly
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Solution Overview
Problem
The existing assembly process for cylindrical lithium-ion batteries is slow and prone to metal debris contamination due to the need to weld through a central hole, which limits production speed and quality.
Innovation Solution
The battery geometry allows for welding the electrical collector to an outer body on the outside of the container, eliminating metal debris inside the container and facilitating quality control inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed through the central hole of the electrochemical cell, then the electrical connection is established, but the production speed is reduced and metal debris contamination occurs
Solution Approach 1:
Instead of welding through the central hole from the inside, the patent inverts the welding approach by accessing the electrical collector through the container wall from the outside. This reversal eliminates the need to weld through the narrow central hole, enabling faster welding operations while preventing metal debris from contaminating the electrochemical cell interior.
Solution Approach 2:
The patent extracts the welding operation from the constrained central hole environment and relocates it to the container wall interface. By taking out the welding process from the problematic central hole location, the solution enables faster welding speeds and prevents debris generation inside the cell while maintaining reliable electrical connection.
2Reliability
If welding is performed through the central hole, then the electrical connection is established, but metal debris contaminates the electrochemical cell
Solution Approach 1:
The patent converts the potential harm of metal debris generation into a beneficial outcome by changing the welding location. The welding process still establishes reliable electrical connection, but by performing it outside the electrochemical cell through the container wall, any metal debris is generated outside the cell, preventing contamination while maintaining connection quality.
Solution Approach 2:
The container wall serves as an intermediary element that enables the welding operation. It provides access to the electrical collector without requiring penetration through the central hole, thus mediating between the need for electrical connection and the need to prevent debris contamination inside the cell.
3Reliability
If welding is performed through the central hole, then the electrical connection is established, but quality control inspection becomes difficult
Solution Approach 1:
The patent inverts the welding location from the inaccessible central hole to the accessible container wall interface. This inversion makes the weld visible and accessible for quality control inspection while still establishing the necessary electrical connection between the electrical collector and the terminal.
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 approach enables high-speed production of cylindrical batteries while ensuring high-quality end products by preventing metal debris contamination and allowing for easier inspection of welds.
Implementation Method 1
the weld between the cathodic electrical collector and the counter-head of the rivet is made by using the central hole (with reduced dimensions) of the electrochemical cell to apply heat to the cathodic electrical collector and therefore melt the metal (aluminium) locally
Data Source
AI summary
An energy storage battery comprising: an electrochemical cell; an electrical collector which is coupled to an end of the electrochemical cell; a container which has a first wall and houses, on the inside, the electrochemical cell so that the electrical collector is arranged close to the first wall; an outer body, which constitutes an electrical pole of the battery and is arranged on an outer surface of the first wall; and a weld which establishes an electrical connection between the electrical collector and the outer body; wherein the weld is at least partially arranged on the outside of the container.