Cylindrical Battery Cover Assembly for Squeeze-Resistant Collector Welding
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Solution Overview
Problem
Large cylindrical batteries face connection failure issues due to squeezing during the encapsulation process, where the first current collector is welded to the sidewall of the case.
Innovation Solution
A secondary battery design that eliminates the connection between the first current collector and the sidewall of the case, instead integrating the first current collector and first cover plate by welding before assembly, allowing for secure welding through the cover plate's through hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first current collector is welded to the sidewall of the case, then the electrical connection is established, but the connection may fail due to squeezing force during encapsulation
Solution Approach 1:
The patent extracts the first current collector from the case sidewall and relocates it to the cover assembly. The first current collector is now welded to the first cover plate instead of the case sidewall, removing it from the high-stress encapsulation zone while maintaining its electrical connection function through the cover plate pathway.
Solution Approach 2:
The first cover plate serves as an intermediary component between the first current collector and the case. The first current collector is welded to the first cover plate, which in turn is welded to the case sidewall, distributing the mechanical stress and protecting the electrical connection from direct squeezing forces during encapsulation.
2Reliability
If the first current collector is welded to the sidewall of the case, then the electrical connection is established, but the assembly process becomes complex with roll-grooving and pier-sealing requirements
Solution Approach 1:
The patent segments the battery assembly into distinct modules: the first cover assembly (containing the first cover plate and first current collector), the second cover assembly, and the case. This modular segmentation allows each component to be assembled and welded independently, eliminating the need for complex roll-grooving and pier-sealing operations that would be required for integrated designs.
Solution Approach 2:
The first current collector is pre-positioned and welded to the first cover plate before the encapsulation process. This preliminary action completes the electrical connection setup in advance, avoiding the need for subsequent complex piercing or grooving operations through the case wall.
3Reliability
If the first current collector is welded to the sidewall of the case, then the electrical connection is established, but the electrode assembly may be damaged during encapsulation
Solution Approach 1:
The first current collector is extracted from the dangerous zone near the case sidewall and relocated to the first cover plate. This extraction removes it from the path of squeezing forces applied during encapsulation, preventing damage to both the current collector and the electrode assembly it connects to.
Solution Approach 2:
The first cover plate acts as a protective barrier that cushions the first current collector from squeezing forces during encapsulation. By positioning the current collector behind this protective layer and away from direct compression zones, the design preemptively protects against mechanical damage.
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 design alleviates connection failures during encapsulation, simplifies the assembly process, reduces the risk of damage to the electrode assembly, and enhances the spatial usage of the battery by eliminating the need for roll-grooving and pier-sealing processes.
Implementation Method 1
The first current collector is connected with the first tab by welding
Implementation Method 2
The first cover plate covers the opening and is connected with the sidewall by welding
Implementation Method 3
The first cover plate is connected with the first current collector by welding
Implementation Method 4
The second cover plate is welded to the first cover plate and seals the through hole
Data Source
AI summary
A secondary battery pack includes a case, a terminal, an electrode assembly, a first current collector, and a cover assembly. The case includes an end wall and a sidewall surrounding the end wall. An opening is formed at an end of the sidewall. The terminal passes through and is insulated from the end wall. The electrode assembly is accommodated in the case and includes a first tab and a second tab electrically connected with the terminal. The first current collector is disposed at an end of the electrode assembly facing the opening and connected with the first tab by welding. The cover assembly includes first and second cover plates. The first cover plate covers the opening, is connected with the sidewall and the first current collector by welding, and includes a through hole. The second cover plate is welded to the first cover plate and seals the through hole.