Sealed Battery Shield Structure for Laser Welded Insulator Protection
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Solution Overview
Problem
High-energy-density batteries face issues during laser welding, where reflected laser light and spatters can cause the insulator to degrade, leading to reduced insulating capacity and airtightness.
Innovation Solution
A sealed battery design incorporating shields along the peripheral edge of the insulator, with a first shield portion extending vertically to block reflected laser light and a second shield portion bent to cover the insulator, preventing contact with spatters during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is performed on the fitted portion between the battery case and the closing plate, then the airtightness of the battery is improved, but the insulator may be seared by reflected laser light or spatters, leading to degradation of insulating capacity
Solution Approach 1:
A shield made of heat-resistant material is introduced as an intermediary component between the laser welding zone and the insulator. The shield has a first shield portion that blocks reflected laser light and a second shield portion that prevents spatters from reaching the insulator, thereby protecting the insulator without interfering with the welding process that ensures airtightness
Solution Approach 2:
The shield is positioned in advance before laser welding begins. The shield extends from the closing plate toward the insulator, pre-establishing a protective barrier that will intercept reflected laser light and spatters before they can reach and sear the insulator during the welding operation
2Quantity of substance
If the distance between the collector terminal and the fitted portion is reduced to achieve high energy density, then the battery energy density is improved, but the insulator becomes more vulnerable to laser light and spatters
Solution Approach 1:
The shield serves as a protective intermediary that enables the insulator to withstand closer proximity to the welding zone. By blocking reflected laser light and spatters, the shield allows the design to achieve high energy density through reduced spacing without compromising insulator integrity
Solution Approach 2:
The shield converts the potentially harmful environment (reflected laser light and spatters) into a controlled situation where the heat-resistant material of the shield absorbs and redirects these harmful factors away from the insulator, allowing the close spacing needed for high energy density
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 shields effectively prevent searing of the insulator, maintaining its insulating capacity and the battery's airtightness by blocking reflected light and spatters during the laser welding process.
Implementation Method 1
reflected laser light may be applied to an insulator
Implementation Method 2
During laser welding, high-temperature molten metal may become fine particles (which are known as 'spatters')
Implementation Method 3
high-temperature molten metal may become fine particles
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A sealed battery (100) includes: a battery case (11) including an opening (12); a closing plate (15) closing the opening (12); a collector terminal (30) including an external connector (34) exposed at an outer surface (17) of the closing plate (15); a resin insulator (40) insulating the closing plate (15) from the external connector (34); a laser-welded region (14W) formed on a fitted portion (14) between the battery case (11) and the closing plate (15); and a shield (19). The shield (19) includes: a first shield portion (19a) extending vertically or substantially vertically from the outer surface (17) of the closing plate (15) and located between the fitted portion (14) and the insulator (40); and a second shield portion (19b) extending from the first shield portion (19a) to the insulator (40) and covering a portion of a surface of the insulator (40).