Vertical Welding Rod Fastening to Reduce Spatter in Battery Welding
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Solution Overview
Problem
The spattering phenomenon occurs due to incorrect welding angles in secondary batteries, where fine metal particles scatter around the welded portion because the welding rod is not fixed perpendicularly to the welding surface, leading to low-voltage failures.
Innovation Solution
A welding rod fastening method and device that uses two fixing screws with opposite tightening directions to secure the welding rod perpendicularly to the welding surface, ensuring proper vertical alignment and reducing positional deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fixing screw is used to secure the welding rod, then the device complexity is reduced, but the welding rod cannot be fixed perpendicularly to the welding surface, causing spattering phenomenon
Solution Approach 1:
The single fixing screw is segmented into multiple fixing screws (at least two) distributed around the welding rod housing hole. This segmentation allows each screw to apply fixing force from different directions, collectively achieving perpendicular fixation of the welding rod while reducing individual screw load and improving overall fixing precision.
Solution Approach 2:
The fixing screws are asymmetrically positioned around the welding rod housing hole rather than using a single symmetric fixing point. This asymmetric distribution of multiple screws enables better control over the welding rod's orientation, ensuring it remains perpendicular to the welding surface during the welding process.
2Ease of operation
If the welding rod is not fixed perpendicularly, then the ease of operation is improved (easier to insert), but the spattering phenomenon occurs due to incorrect welding angle
Solution Approach 1:
The welding rod is preliminarily positioned and fixed perpendicularly to the welding surface before the welding operation begins. The multiple fixing screws are pre-tightened to ensure the welding rod maintains the correct perpendicular angle throughout the welding process, preventing spattering from occurring in the first place rather than correcting it afterward.
3Manufacturing precision
If multiple fixing screws are used to ensure perpendicularity, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The fixing screws are strategically positioned at specific locations around the welding rod housing hole where they provide maximum rotational stability. This localized placement optimizes the fixing effect, ensuring perpendicularity is achieved with the minimum necessary number of screws rather than uniformly distributing screws throughout the structure.
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 effectively reduces the spattering phenomenon by maintaining the welding rod's perpendicularity, thereby enhancing the contact area and preventing excessive melting during the welding process.
Implementation Method 1
fastening fixing screws to spaces on opposite sides of the welding rod housing hole on the basis of the welding rod to tighten the welding rod housing hole
Implementation Method 2
resistance welding (welding which turns the joint part into a semi-melting state by the resistance heat generated by applying a large current to a joint part of a base material)
Implementation Method 3
resistance welding (welding which turns the joint part into a semi-melting state by the resistance heat generated by applying a large current to a joint part of a base material)
Data Source
AI summary
A welding rod fastening method capable of fixing the welding rod perpendicularly to a welding surface to reduce a spattering phenomenon in which fine metal particles scatter around a welded portion due to an incorrect welding angle when welding, and a welding device in which the welding rod is fastened vertically thereby. The welding rod fastening method is a method for fixing a welding rod to a welding rod fixing block having a welding rod housing hole formed therein, and includes inserting the welding rod into a welding rod housing hole of the welding rod fixing block, and fastening fixing screws to spaces on both sides of the welding rod housing hole on the basis of the welding rod to tighten the welding rod housing hole. The fixing screws fastened to the spaces on both sides of the welding rod housing hole are tightened in tightening directions that are opposite to each other.