Cylindrical battery and assembly process thereof
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Solution Overview
Problem
Conventional cylindrical batteries have complex structures that lead to multiple processing procedures, high costs, and low efficiency due to complex assembly steps and the need for multiple welding processes, which affect power performance and service life.
Innovation Solution
A cylindrical battery design featuring a multi-petal current collector with a conductive handle and thermosetting conductive adhesive, along with a simplified assembly process that reduces mechanical parts and welding processes, uses a conductive adhesive to connect the roll core to the case, and employs a sealing ring for improved electrical and thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser penetration welding is performed on the current collector and the bottom of the case, then welding connection is achieved, but the welding parameters are unfixed and there is a risk of damaging roll cores
Solution Approach 1:
The patent replaces laser penetration welding with ultrasonic welding technology. This substitution changes the welding mechanism from thermal-melting-based to mechanical-vibration-based, eliminating the need for complex parameter adjustments and multiple welding trials. The ultrasonic welding process provides more stable and controllable welding quality without risking damage to the roll core, thus improving process reliability while maintaining welding connection strength.
2Strength
If multiple welding processes are used for assembly, then connection strength is achieved, but assembly complexity and cost increase
Solution Approach 1:
The patent merges multiple separate welding processes into a single integrated ultrasonic welding step. By combining the welding of current collector to case bottom, current collector to cap, and other connections into one unified ultrasonic welding operation, the assembly process complexity is significantly reduced while maintaining all necessary connection strengths. This consolidation eliminates multiple welding parameters and steps, simplifying the overall assembly process.
3Reliability
If conventional welding methods are used, then electrical connection is achieved, but power performance is limited due to small welding spots
Solution Approach 1:
The patent transitions from point-based welding spots to area-based ultrasonic welding zones. Instead of relying on small discrete welding points, the ultrasonic welding creates extended welding areas that provide both mechanical strength and electrical conductivity. This dimensional expansion from 0D points to 2D areas simultaneously improves electrical connection reliability and power performance by providing larger contact areas for current flow.
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 solution results in a battery with reduced assembly complexity, lower costs, and enhanced power performance, enabling large-power use with improved reliability and stability, while minimizing the risk of damage from height errors and ensuring effective bonding of the conductive adhesive.
Implementation Method 1
a bottom of the roll core is fixedly connected to the case through the conductive adhesive
Implementation Method 2
a conductive adhesive, a roll core
Implementation Method 3
petal elements of the current collector are welded with the roll core, a conductive handle of the current collector is welded with the cap
Data Source
AI summary
A cylindrical battery includes a case with an opening defined in an end thereof, and a conductive adhesive, a roll core, a current collector, an insulating element, and a cap sequentially disposed inside the case from bottom to top; the insulating element is sleeved on the current collector; the current collector is of a multi-petal structure, and is provided with a positioning structure respectively connected to the roll core and the cap; after being limited, petal elements of the current collector are welded with the roll core; a conductive handle of the current collector is welded with the cap; a roll groove is defined on an outside of the case; the roll groove is positioned outside a current collector body; and a bottom of the roll core is fixedly connected to the case through the conductive adhesive.