Dual-Protrusion Welding Plate for Cylindrical Battery Re-Welding
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Solution Overview
Problem
Conventional metal plates for resistance welding of cylindrical batteries often result in welding defects such as under-welding, non-welding, or over-welding, making re-welding impossible and leading to increased manufacturing costs due to discarded batteries.
Innovation Solution
A metal plate with two protrusions of different diameters, positioned on the same axis, allows for re-welding at the same position using a single metal plate, enabling successful welding even after primary welding defects occur, reducing the number of discarded batteries and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional metal plate with a single protrusion is used for resistance welding, then the welding process is simple, but welding defects occur and re-welding is impossible
Solution Approach 1:
The metal plate's protrusion is segmented into multiple protrusion units (first, second, and third protrusion units) with different diameters arranged along the thickness direction. This segmentation allows selective use of different protrusion units for welding, enabling re-welding if the first welding attempt fails, thereby improving welding reliability without requiring a completely complex new structure.
Solution Approach 2:
The metal plate is pre-equipped with multiple protrusion units of different diameters before the welding process. This preliminary preparation ensures that if the first welding attempt using a specific protrusion unit fails, alternative protrusion units are already in place for re-welding, eliminating the need for plate replacement and improving production efficiency.
2Ease of manufacture
If a single-protrusion metal plate is used, then the manufacturing process is simple, but welding defects lead to increased manufacturing costs
Solution Approach 1:
The protrusion is divided into multiple protrusion units with different diameters, allowing the metal plate to accommodate varying welding requirements. This segmentation reduces the discard rate of batteries due to welding defects while maintaining manufacturing simplicity through a unified plate structure with integrated multiple功能的 protrusion units.
Solution Approach 2:
The metal plate incorporates protrusion units with different diameter parameters (first, second, and third protrusion units having progressively different diameters). This parameter variation within a single plate structure allows optimization for different welding scenarios, reducing battery waste while keeping the manufacturing process relatively simple.
3Ease of repair
If multiple protrusions of different diameters are added to the metal plate, then re-welding becomes possible, but the metal plate structure becomes more complex
Solution Approach 1:
The protrusion is segmented into multiple protrusion units arranged in the thickness direction, with each unit having a different diameter. This segmentation enables re-welding capability by allowing selection of appropriate protrusion units based on welding outcomes, while the integrated design within a single plate minimizes the increase in overall structural complexity.
Solution Approach 2:
The multiple protrusion units are nested along the thickness direction of the metal plate, with smaller diameter units positioned within the spatial envelope of larger diameter units. This nesting arrangement enables re-welding functionality while minimizing the increase in the metal plate's external dimensions and overall structural complexity.
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 metal plate design enables successful re-welding at the same position, reducing battery discards and production costs by allowing for secondary welding using a single metal plate, thereby improving the reliability and efficiency of the resistance welding process.
Implementation Method 1
resistance welding while pressing the upper part of an electrode terminal 110 of a cylindrical battery 100 and a protrusion 215 of the metal plate 200 using a welding rod
Data Source
AI summary
Discussed are a metal plate for resistance welding and a resistance welding method using the same, wherein the metal plate is for being resistance-welded to an electrode terminal of a cylindrical battery, and the metal plate includes a body; and a pair of protrusion units located spaced apart from each other by a predetermined distance, the pair of protrusion unit being provided at one side surface of the body, and a slit is formed between the pair of protrusion units.