External Battery Collector Welding to Prevent Cell Contamination

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Solution Overview

Problem

The conventional method of welding the electrical collector to the rivet inside the cylindrical battery container is slow, prone to metal splashes that contaminate the cell, and difficult to inspect, limiting production speed and quality.

Innovation Solution

A method where the weld is made externally between the electrical collector and the outer body of the battery, eliminating internal metal debris and facilitating inspection, thereby increasing production speed and ensuring high-quality end products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is performed through the central hole of the electrochemical cell from the inside of the container, then the electrical connection is established, but the production speed is slow and metal splashes contaminate the cell

Engineering Contradiction:

Improvewelding qualityVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent inverts the conventional welding approach by performing the welding operation from the outside of the container rather than from the inside through the central hole. The electrical collector is welded to the rivet through the container wall from the external side, which eliminates metal splash contamination inside the cell while enabling faster production. This inversion of the welding direction resolves the contradiction between maintaining welding quality and increasing production speed.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If welding is performed through the central hole of the electrochemical cell, then the electrical connection is established, but metal splashes contaminate the cell interior

Engineering Contradiction:

Improveelectrical connectionVSAvoidmetal splash contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent reverses the welding direction to perform the operation from the outside of the container. By welding the electrical collector to the rivet through the container wall from the external side, the process prevents metal splashes from entering the cell interior, thereby eliminating contamination while maintaining reliable electrical connection.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The harmful factor of metal splash contamination is extracted from the system by changing the welding location to the external side of the container. The welding process is separated from the internal cell environment, so that any metal splashes occur outside the container and do not affect the cell interior, thus removing the harmful effect while preserving the electrical connection function.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If welding is performed through the central hole from the inside, then the electrical connection is made, but inspection becomes difficult

Engineering Contradiction:

Improveelectrical connectionVSAvoidweld inspection difficulty

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent inverts the welding approach by performing the operation from the outside of the container. This external welding location makes the weld accessible for inspection from the exterior, eliminating the difficulty of detecting and measuring weld quality that arises when welding is performed through the narrow central hole from the inside.

Inventive Principle:

Principle #13The other way round (Inversion)

4Reliability

If conventional welding through the central hole is used, then the electrical connection is established, but production speed is limited

Engineering Contradiction:

Improvewelding qualityVSAvoidwelding time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent reverses the welding direction to perform the operation from the outside of the container. This external welding approach eliminates the time-consuming constraints of working through the narrow central hole, allowing for faster welding operations while maintaining welding quality, thus reducing the loss of time in the production process.

Inventive Principle:

Principle #13The other way round (Inversion)

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 method allows for higher production speeds while maintaining high-quality batteries by preventing internal contamination and simplifying quality control, thus enhancing the overall efficiency and reliability of the battery production process.

Implementation Method 1

making a weld between the electrical collector and the outer body in order to establish an electrical connection

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20250141070A1Method to produce a battery for energy storage

Publication Date: 2025.05.01 GD SPA

AI summary

A method to produce an energy storage battery comprising the steps of: providing an electrochemical cell, which is at least partially complete and is provided with an electrical collector; providing a container having a first wall; placing, on an outer surface of the first wall, an outer body, which constitutes an electrical pole of the battery; and inserting the electrochemical cell into the container placing the electrical collector close to the first wall; andmaking a weld between the electrical collector and the outer body in order to establish an electrical connection; wherein the weld is made from the outside of the container operating from the opposite side of the first wall relative to the electrochemical cell.