Method of laser welding the housing of a rechargeable battery
First Claim
1. A method of assembling a rechargeable battery, said method including the step of:
- providing a first housing component, the first housing component formed from a polyphenysulfone plastic that does not appreciably interfere with the transmission of photonic energy at a select wavelength and that is formed to have an outer surface, an edge around the outer surface and an inner face that extends from the edge and is located inwardly from the outer surface;
providing a second housing component, the second housing component formed from a polyphenysulfone plastic that absorbs photonic energy emitted at the select wavelength and that is formed to have an outer surface and a lip that extends outwardly from and is located inwardly of the outer surface of the second housing component and wherein the first and second housing components are collectively shaped so that when the housing components are placed together;
the lip of the second housing component abuts the inner face of the first housing component; and
adjacent where the lip and the inner face of the first housing component abut there is a void, the void being located inwardly of the outer surfaces of the housing components;
placing at least one rechargeable cell in one of the housing components and connecting the cell to terminals mounted to one of the housing components;
placing the housing components together so the lip of the second housing component abuts the inner face of the first housing component;
directing photonic energy at the select wavelength towards the outer surface of the first housing component so that the photonic energy passes through the first housing component and is absorbed by the lip of the second housing component, so that;
the photonic energy heats the lip so as to cause the melting of the lip and the transfer of thermal energy to the first housing component so as to form a weld joint along the interface between where the lip of the second housing component abuts the inner face of the first housing component; and
flash formed by said welding flows into the void between the first and second housing components.
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Accused Products
Abstract
A rechargeable battery including a housing formed from two components formed from polyphenysulfone plastic. One housing component has a lip that is located inwardly of the other housing component. The housing components are further formed so that photonic energy at a select wavelength passes through the outer component and is absorbed by the lip of the second component. Once a rechargeable cell is placed in in one of the housing components, the housing components are placed together so the lip of the second component abuts an inner surface of the first component. Photonic energy at the select wavelength is directed to the joint between the components. The photonic energy passes through the first component and heats the lip of the second component. The heat causes the lip to melt. The melting plastic forms a hermetic weld between the housing components.
40 Citations
23 Claims
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1. A method of assembling a rechargeable battery, said method including the step of:
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providing a first housing component, the first housing component formed from a polyphenysulfone plastic that does not appreciably interfere with the transmission of photonic energy at a select wavelength and that is formed to have an outer surface, an edge around the outer surface and an inner face that extends from the edge and is located inwardly from the outer surface; providing a second housing component, the second housing component formed from a polyphenysulfone plastic that absorbs photonic energy emitted at the select wavelength and that is formed to have an outer surface and a lip that extends outwardly from and is located inwardly of the outer surface of the second housing component and wherein the first and second housing components are collectively shaped so that when the housing components are placed together;
the lip of the second housing component abuts the inner face of the first housing component; and
adjacent where the lip and the inner face of the first housing component abut there is a void, the void being located inwardly of the outer surfaces of the housing components;placing at least one rechargeable cell in one of the housing components and connecting the cell to terminals mounted to one of the housing components; placing the housing components together so the lip of the second housing component abuts the inner face of the first housing component; directing photonic energy at the select wavelength towards the outer surface of the first housing component so that the photonic energy passes through the first housing component and is absorbed by the lip of the second housing component, so that; the photonic energy heats the lip so as to cause the melting of the lip and the transfer of thermal energy to the first housing component so as to form a weld joint along the interface between where the lip of the second housing component abuts the inner face of the first housing component; and flash formed by said welding flows into the void between the first and second housing components. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A rechargeable battery manufactured according to the steps of:
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providing a first housing component, the first housing component formed from a polyphenysulfone plastic that does not appreciably interfere with the transmission of photonic energy at a select wavelength and that is formed to have an outer surface, an edge around the outer surface and an inner face that extends from the edge and that is located inwardly from the outer surface; providing a second housing component, the second housing component formed from a polyphenysulfone plastic that absorbs photonic energy emitted at the select wavelength and that is formed to have an outer surface and a lip that extends outwardly from and is located inwardly of the outer surface of the second housing component and wherein the first and second housing components are collectively shaped so that when the housing components are placed together;
the lip of the second housing component abuts the inner face of the first housing component;placing at least one rechargeable cell in one of the housing components and connecting the cell to terminal components mounted to one of the housing components; placing the housing components together so the lip of the second housing component abuts the inner face of the first housing component so that the first housing component surrounds the lip of the second housing component; and directing photonic energy at the select wavelength towards the outer surface of the first housing component so that the photonic energy passes through the first housing component and is absorbed by the lip of the second housing component, so that the photonic energy heats the lip so as to cause the melting of the lip and the transfer of the thermal energy to the first housing component so as to form a weld joint along the interface between where the lip of the second housing component abuts the inner face of the first housing component so that the weld joint forms a hermetic seal between the housing components and the weld joint is located inwardly of the outer surfaces of the housing components. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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Specification