Wear-Resistant Welding Clamp for Battery Case Deformation Control
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Solution Overview
Problem
The existing welding clamps used in battery manufacturing cause wear and deformation of the case during the welding process, leading to increased maintenance costs, reduced structural strength, and compromised appearance of the battery cell.
Innovation Solution
A welding clamp with detachable clamping portions and a wear-resistant layer that contacts the case to prevent wear and deformation, featuring a thickness of 0.1mm≤h≤1mm, made from materials like Teflon or polyimide, and a bonding layer with a melting point of A≥180°C to ensure stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional welding fixtures are used, then welding operations can be performed, but the fixtures generate harmful emissions and waste materials during the welding process
Solution Approach 1:
A vacuum chamber serves as an intermediary environment that isolates the welding process from the external atmosphere. The chamber creates a controlled vacuum environment where welding occurs, preventing harmful emissions and contaminants from being released into the surrounding workspace while maintaining welding productivity.
Solution Approach 2:
The invention converts the potentially harmful welding emissions and debris into a contained system where these byproducts are captured and controlled. The vacuum environment transforms what would be harmful atmospheric contamination into a manageable internal chamber condition that can be filtered and controlled.
2Manufacturing precision
If welding fixtures are used to hold workpieces, then positioning is achieved, but the fixtures complicate the overall welding system and increase device complexity
Solution Approach 1:
The welding fixture, vacuum chamber, and workpiece clamping system are merged into a single integrated unit. The fixture serves multiple functions simultaneously: it positions workpieces with high precision, maintains vacuum sealing, and provides clamping mechanisms. This consolidation reduces the number of separate components and simplifies the overall system architecture.
Solution Approach 2:
The welding fixture is designed as a multi-functional component that performs positioning, clamping, and vacuum sealing functions. This universal fixture can accommodate different workpiece configurations and sizes while maintaining positioning accuracy, eliminating the need for multiple specialized fixtures for different welding scenarios.
3Manufacturing precision
If complex welding fixtures are used to achieve precise positioning, then manufacturing precision is improved, but the fixtures become difficult to operate and reduce ease of operation
Solution Approach 1:
The welding fixture incorporates dynamic, adjustable elements that allow operators to easily modify positioning and clamping configurations. The fixture features movable components and adjustable mechanisms that can be quickly repositioned to accommodate different workpiece sizes and geometries, maintaining precision while improving operational ease through simple adjustment procedures.
Data Source
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AI summary
The present application provides a welding clamp, and relates to the technical field of battery manufacturing. The welding clamp includes a plurality of clamping portions used to fit and clamp a case of a battery cell, the clamping portion includes a body portion and a connecting portion, and the connecting portion is detachably connected to the body portion; and a wear-resistant layer is connected to a surface of the connecting portion facing the case. In the process of welding the case and the end cover of the battery cell, through fitting and clamping the case by the clamping portion of the welding clamp, the clamping portion can play a position-limit role to the wall of the case to relieve the deformation of the case during the welding process, thereby improving the welding quality of the case and the end cover and thus improving the production quality of the battery cell. The wear-resistant layer is in contact with the case, so as to avoid wear of the clamping portion due to direct contact of the clamping portion with the case, thereby prolonging the service life of the clamp and reducing the cost of maintaining and replacing the welding clamp. The provision of the wear-resistant layer can also alleviate the problem that the welding clamp scratches the case, which reduces the structural strength of the case and affects the appearance of the case.