Manufacturing process for square battery cell

Abstract

A method for manufacturing an enclosure includes designing a two-dimensional (2D) blank corresponding to a three-dimensional (3D) enclosure body; planning N 2D blanks on the metal plate, wherein N is an integer greater than 1; separating the N 2D blanks from the metal plate; bending and / or folding the N 2D blanks into a 3D shell main body; and a plurality of edges connecting the 3D housing body.

Description

Technical Field

[0001] The present disclosure relates to battery cells, and more particularly to methods for making housings for prismatic battery cells. Background Art

[0002] The information provided in this section is for the purpose of generally introducing the background of the present disclosure. To the extent described in this section, the work of the presently named inventors and aspects of the description that may not constitute prior art at the time of filing are neither explicitly nor implicitly admitted as prior art against the present disclosure.

[0003] Electric vehicles (EVs), such as battery electric vehicles (BEVs), hybrid vehicles, and / or fuel cell vehicles, include one or more motors and a battery system including one or more battery cells, modules, and / or battery packs. A power control system is used to control the charging and / or discharging of the battery system during charging and / or driving. Summary of the invention

[0004] A method for manufacturing a shell includes designing a two-dimensional (2D) blank corresponding to a three-dimensional (3D) shell body; planning N 2D blanks on a metal plate, where N is an integer greater than 1; separating the N 2D blanks from the metal plate; at least one of bending the N 2D blanks into a 3D shell body and folding the N 2D blanks into the 3D shell body; and connecting multiple edges of the 3D shell body.

[0005] In other features, the method includes coating the metal sheet with an insulating layer. The N 2D blanks also include a cover. The method also includes arranging the battery cell stack in the 3D housing body; folding the cover to cover an opening of the 3D housing body, and connecting at least one edge of the cover to the opening in the 3D housing body.

[0006] In other features, the cover includes at least one of a first opening for a terminal and a second opening for a vent. The method includes, after connecting a plurality of edges of the 3D housing body, arranging the battery cell stack in the 3D housing body. The method includes connecting the cover to the opening of the 3D housing body.

[0007] In other features, the cover is connected to the 3D housing body using at least one of laser welding, crimping, and brazing using a copper welding wire. At least one of the multiple edges of the 3D housing body is ironed and solid-state connected. At least one of the multiple edges of the 3D housing body is laser welded. At least one of the multiple edges of the 3D housing body is connected using at least one of laser welding, electron beam welding, brazing using a copper welding wire, and induction welding. At least one of the N 2D blanks includes a first complementary flange portion and a second complementary flange portion, which are aligned, mated, and connected after at least one of bending and forming.

[0008] In other features, at least one of the N 2D blanks includes rounded corners to prevent holes from appearing after folding and connecting. At least one of the N 2D blanks includes a side portion that includes a protrusion to prevent holes from appearing after folding and connecting. The metal sheet is made of a material selected from the group consisting of steel, stainless steel, and aluminum.

[0009] A method for manufacturing a housing includes providing a two-dimensional (2D) blank corresponding to a three-dimensional (3D) housing body and a cover at least partially attached to the 3D housing body; bending the 2D blank into the 3D housing body and at least one step of folding the 2D blank into the 3D housing body; connecting the edges of the 3D housing body; arranging a battery cell stack within the 3D housing body; and connecting at least one edge of the cover to the 3D housing body.

[0010] In other features, the 2D blank includes an insulating layer. The cover includes at least one of a first opening for a terminal and a second opening for a vent. At least one edge of the cover is connected to the 3D housing body using at least one of laser welding, crimping, and brazing using a copper welding wire. The 2D blank is made of a material selected from the group consisting of steel, stainless steel, and aluminum.

[0011] A method for manufacturing a housing includes providing a two-dimensional (2D) blank corresponding to a three-dimensional (3D) housing body; at least one of bending the 2D blank into the 3D housing body and folding the 2D blank into the 3D housing body; connecting the edges of the 3D housing body using ironing and solid-state connection; arranging a battery cell stack within the 3D housing body; and connecting a cover to the 3D housing body.

[0012] In other features, the cover includes at least one of a first opening for a terminal and a second opening for a vent. At least one edge of the cover is connected to the 3D housing body using at least one of laser welding, crimping, and brazing using a copper welding wire. The 2D blank is made of a material selected from the group consisting of steel, stainless steel, and aluminum, and the 2D blank includes an insulating layer.

[0013] The present invention provides the following technical solutions:

[0014] 1. A method for manufacturing a housing, comprising:

[0015] designing a two-dimensional (2D) blank corresponding to a three-dimensional (3D) housing body;

[0016] Planning N 2D blanks on the metal plate, where N is an integer greater than 1;

[0017] Separating N 2D blanks from the metal sheet;

[0018] bending and / or folding the N 2D blanks into a 3D housing body; and

[0019] Connect multiple edges of the 3D shell body.

[0020] 2. The method according to Option 1 also includes coating the metal plate with an insulating layer.

[0021] 3. The method according to claim 2, wherein the N 2D blanks further include a cover, and the method further comprises:

[0022] Arranging a battery cell stack within the 3D housing body; and

[0023] The cover is folded to cover the opening of the 3D housing body, and at least one edge of the cover is connected to the opening in the 3D housing body.

[0024] 4. The method according to claim 3, wherein the cover includes at least one of a first opening for a terminal and a second opening for a vent.

[0025] 5. The method according to claim 1 further comprises:

[0026] After connecting the plurality of edges of the 3D housing body, arranging the battery cell stack in the 3D housing body; and

[0027] Attach the cover to the opening of the 3D housing body.

[0028] 6. The method according to claim 5, wherein the cover is connected to the 3D housing body using at least one of laser welding, crimping, and brazing using a copper welding wire.

[0029] 7. The method according to claim 1, wherein at least one of the plurality of edges of the 3D shell body is ironed and solidly connected.

[0030] 8. A method according to Option 7, wherein at least one of the multiple edges of the 3D shell body is laser welded.

[0031] 9. The method according to claim 1, wherein at least one of the plurality of edges of the 3D housing body is connected using at least one of laser welding, electron beam welding, brazing using a copper welding wire, and induction welding.

[0032] 10. A method according to Option 1, wherein at least one of the N 2D blanks includes a first complementary flange portion and a second complementary flange portion, and the first complementary flange portion and the second complementary flange portion are aligned, matched and connected after at least one of the bending and forming.

[0033] 11. The method of claim 1, wherein at least one of the N 2D blanks comprises rounded corners to prevent holes from appearing after folding and connecting.

[0034] 12. A method according to scheme 1, wherein at least one of the N 2D blanks includes a side portion, and the side portion includes a protrusion to prevent the appearance of holes after folding and connecting.

[0035] 13. The method according to Option 1, wherein the metal plate is made of a material selected from the group consisting of steel, stainless steel and aluminum.

[0036] 14. A method for manufacturing a housing, comprising:

[0037] providing a two-dimensional (2D) blank corresponding to a three-dimensional (3D) housing body and a cover at least partially attached to the 3D housing body;

[0038] bending and / or folding the 2D blank into a 3D housing body;

[0039] Connect the edges of the 3D shell body;

[0040] Arranging a battery cell stack within the 3D housing body; and

[0041] At least one edge of the cover is connected to the 3D housing body.

[0042] 15. A method according to claim 14, wherein the 2D blank comprises an insulating layer.

[0043] 16. The method according to claim 14, wherein:

[0044] The cover includes at least one of a first opening for the terminal and a second opening for the vent, and

[0045] At least one edge of the cover is connected to the 3D housing body using at least one of laser welding, crimping, and brazing using a copper welding wire.

[0046] 17. A method according to Option 14, wherein the 2D blank is made of a material selected from the group consisting of steel, stainless steel and aluminum.

[0047] 18. A method for manufacturing a housing, comprising:

[0048] providing a two-dimensional (2D) blank corresponding to a three-dimensional (3D) housing body;

[0049] bending and / or folding the 2D blank into a 3D housing body;

[0050] Use ironing and solid connection to connect the edges of the 3D shell body;

[0051] Arranging a battery cell stack within the 3D housing body; and

[0052] Attach the cover to the 3D housing body.

[0053] 19. The method according to claim 18, wherein:

[0054] The cover includes at least one of a first opening for the terminal and a second opening for the vent, and

[0055] At least one edge of the cover is connected to the 3D housing body using at least one of laser welding, crimping, and brazing using a copper welding wire.

[0056] 20. The method according to claim 18, wherein:

[0057] The 2D blank is made of a material selected from the group consisting of steel, stainless steel and aluminum, and

[0058] The 2D blank comprises an insulating layer.

[0059] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] The present disclosure will be more fully understood from the detailed description and accompanying drawings, in which:

[0061] Figure 1 is a side cross-sectional view of an example of a battery cell according to the present disclosure, the battery cell including a cathode electrode, an anode electrode, and a separator arranged in a battery cell housing;

[0062] Figure 2A is a perspective view of an example of a square battery cell;

[0063] Figure 2B is a perspective view of an example of a prismatic battery cell having a pressure-based vent cap;

[0064] Figure 3 is a perspective view of an example of a metal sheet providing a plurality of 2D blanks for manufacturing a 3D housing according to the present disclosure;

[0065] FIG. 4A to FIG. 4C is a perspective view of an example of a 2D blank folded and connected into a 3D housing for a prismatic battery cell according to the present disclosure;

[0066] FIG. 5A to FIG. 5C An example of folding and connecting a 3D housing for a prismatic battery cell using a two-piece assembly according to the present disclosure is shown;

[0067] FIG. 6A to FIG. 6C An example of folding and connecting a 3D housing for a prismatic battery cell using a one-piece assembly according to the present disclosure is shown;

[0068] Figures 7 to 9 An example of bending / forming a housing using a die and a punch according to the present disclosure is shown;

[0069] Fig.10 is a perspective view of an example of a 3D shell with a gap;

[0070] Fig.11 and Fig.12 is a plan view showing an example of a 2D blank including additional material such as rounded corners and / or protrusions according to the present disclosure;

[0071] FIG. 13A to FIG. 13C is a perspective view showing another housing fabricated using ironing and solid state joining in accordance with the present disclosure; and

[0072] FIG. 14A to FIG. 14C is an example of a method of manufacturing a 3D housing for a battery cell using a 2D blank according to the present disclosure.

[0073] Among the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0074] Although prismatic battery cells according to the present disclosure are illustrated in the context of electric vehicles, prismatic battery cells may be used in stationary applications and / or other applications.

[0075] To meet the needs of different electric vehicle applications, prismatic battery cell housings can be manufactured using different form factors (including different x-axis, y-axis and / or z-axis dimensions). In some applications, prismatic battery cell housings with high aspect ratios and / or using different materials are required. These size and material requirements pose significant challenges to forming and joining processes (such as forward or backward extrusion previously used to manufacture housings).

[0076] The manufacturing method according to the present disclosure uses a hybrid mold forming and bending process followed by in-line or off-line joining to manufacture a prismatic battery cell housing. The manufacturing method according to the present disclosure provides a universal solution applicable to a variety of sizes and materials for manufacturing prismatic battery cell housings with high productivity.

[0077] In some examples, the 2D blank is designed and planned on a metal sheet. In some examples, the 2D blanks are nested to improve material efficiency and reduce waste. The 2D blank is cut from the metal sheet (e.g., using a die press or other method). The two-dimensional blank is bent or folded into a body. The body is fixed and welded. In some examples, the 2D blank is a one-piece component including a folded and connected cover. In other examples, the 2D blank is a two-piece component, and the cover is connected after the body is manufactured.

[0078] In some examples, the connection includes laser welding the edges of the housing. In some examples, the cover can be attached to the open body of the housing using crimping. In other examples, the connection includes brazing using copper welding wire, electron beam welding, induction welding, or other types of connections.

[0079] In other examples, a 2D blank is designed, planned, and cut from a metal sheet. The two-dimensional blank is bent or folded into a body. Ironing and solid-state joining are used to join the edges of the housing body. In some examples, a supplementary joining step (e.g., laser welding) is optionally performed if desired. Trimming can be optionally performed to remove uneven edges if desired.

[0080] Reference now Figure 1 , the battery cell 10 includes C cathode electrodes 20, A anode electrodes 40, and S separators 32 arranged in a predetermined order in a stack 12 located in a housing 50. The C cathode electrodes 20-1, 20-2, ..., and 20-C (where C is an integer greater than 1) include a cathode active layer 24 arranged on one side or both sides of a cathode current collector 26. The A anode electrodes 40-1, 40-2, ..., and 40-A (where A is an integer greater than 1) include an anode active layer 42 arranged on one side or both sides of an anode current collector 46.

[0081] In some examples, the current collector is made of one or more materials selected from the group consisting of copper, stainless steel, brass, bronze, zinc, aluminum, and / or alloys thereof. In some examples, the external tabs connected to the current collectors of the anode and cathode electrodes are located on opposite sides of the battery stack (e.g., Figure 1 as shown) or on the same side of the battery stack.

[0082] Reference now Figure 2A and Figure 2B , the square battery cell 58 includes a housing 60. In some examples, the housing 60 has a square shape (e.g., a rectangular cross-section in the x-axis, y-axis, and z-axis planes). The housing 60 includes a body 61 and a bottom 86, the body 61 includes a side 80 and a side 82, and the bottom 86 defines an open-ended prism. In some examples, the side 80 has a narrower width than the side 82.

[0083] The cover 84 is attached to the body 61 to close the top opening of the body 61. The square battery cell 58 includes external terminals 62 and 64 passing through the cover 84. Before attaching the cover, the stack 12 consisting of C cathode electrodes 20, anode electrodes 40, and S separators 32 is arranged in the housing 60.

[0084] External terminals 62 and 64 are connected to external tabs of the A anode electrodes 40 and the C cathode electrodes 20, respectively. Figure 2AIn the embodiment, the cover 84 does not include a pressure-based vent cap. Figure 2B In the embodiment of the present invention, the cover 84 (and / or the bottom 86) includes a pressure-based vent cap 66. The pressure-based vent cap 66 is configured to release exhaust gas when the pressure within the inner shell is greater than a predetermined pressure.

[0085] As described above, the method for manufacturing a housing for a square battery cell according to the present disclosure includes various steps, such as 2D blank design, 2D punching, die bending / folding, ironing, online and / or offline connection, and / or trimming. In some examples, all or a major part of the manufacturing process can be performed in a progressive feed line similar to progressive die stamping to achieve high productivity.

[0086] Reference now Figures 3 to 4C , shows an example of a method for manufacturing a housing for a prismatic battery cell. Figure 3 In the embodiment of the present invention, after the shape is determined, one or more 2D blanks 114-1, 114-2, ... and 114-N (where N is an integer greater than 1) are planned on a metal plate 110. In some examples, the metal plate 110 may include steel, stainless steel, coated steel, aluminum, or other materials. In some examples, the metal plate 110 is coated with an optional insulating layer 112.

[0087] 2D blank 114 is designed to have a 2-dimensional (2D) shape to adapt to subsequent bending, folding, ironing, connection and / or trimming operations. In other words, the 2D blank is a 2-dimensional (2D) pattern (in an unfolded state) that is bent, folded and / or connected to form a 3D shell.

[0088] like Figure 4A As shown, the 2D blank 114 is separated from the metal sheet 110. In some examples, the 2D blank 114 includes a first side 120, a second side 122, and a bottom 124 that form an open body. In some examples, the 2D blank 114 is sheared using a 2D blanking die or other techniques such as laser cutting or water jet cutting are used to cut the 2D blank 114. Shearing provides faster 2D blanking speeds and can produce multiple workpieces per cycle to further increase productivity. Figure 4B In FIG. 1 , the 2D blank 114 is folded along its edges (eg, along the dashed lines) and connected as shown. Figure 4C The housing of a prismatic battery cell is shown.

[0089] In some examples, a 2D blank is stamped into a die cavity and conforms to the shape of the die and punch. Bending / folding can include one or more steps such as cutting, crimping, and / or folding. In addition to bending / folding, drawing, stretching, and / or compression can also be performed and designed into the die forming process to achieve the desired features (offset, sealing angle, etc.). For example, a 2D blank can be designed with excess material at the corners and / or protrusions along the edges to eliminate bend relief grooves / eyelets at the corners and / or other locations typical in press brake bend designs.

[0090] Due to the low tonnage requirements of the bent / hemmed material, multiple cans can be formed simultaneously using a multi-cavity mold to increase production rates. These flanges are connected to close the battery cell housing to achieve a hermetic seal and the required connection strength.

[0091] In some examples, use FIG. 5A to FIG. 5C Two-piece assembly and / or Figures 6A to 6C The single-piece assembly in folds and connects the housing for the prismatic battery cells. FIG. 5A to FIG. 5C In the embodiment, after 2D punching, folding and connection, the cover 140 is attached to the opening 141 of the housing. In some examples, the cover 140 includes an opening 142 for the terminal and / or an opening 144 for the vent cap.

[0092] exist FIG. 6A to FIG. 6C , 2D blank 150 also includes material for a cover. 2D blank 150 includes a first side 152, a second side 154, a bottom 156, and a cover 160 connected to one of the second sides 154. After 2D blanking, folding, and connecting, cover 160 is folded along one edge and connected to an opening 161 of the housing. In some examples, cover 160 includes an opening 162 for a terminal and / or an opening 164 for a vent cap.

[0093] In some examples, the edges of the housing are connected using laser welding. In other examples, the cover can be attached to the body of the housing using crimping. In other examples, the edges of the housing are connected by brazing using copper welding wire, electron beam welding, induction welding, or other types of connections.

[0094] Reference now Figures 7 to 9 , dies, punches and / or fixtures may be used to crimp, bend or fold the housing. Figure 7 In the embodiment, a bending machine (not shown), a die 212 and a punch 210 are used to fold, bend and / or fold a 2D blank 214. Figure 8 In the embodiment, a punch 220 and a die 222 are used to perform die bending and folding on a 2D blank 224. Fig. 9 In FIG. 2 , a punch 240 , a die 242 and a fixture 246 are used to draw a 2D blank.

[0095] Reference now Figures 10 to 12 In addition to bending / folding / joining, drawing, stretching and / or compression can also be used. Drawing, stretching and / or compression are integrated into the die forming process to achieve the desired features (offset, sealing angle, etc.). Fig.10 As can be seen in FIG. 3 , the housing 300 may include a first side 310, the first side 310 including a flange 312. The housing 300 includes a second side 313, the second side 313 including a reinforcing bead 318 (e.g., extending inwardly or outwardly) and a flange 314. The housing 300 includes a third side 320, the third side 320 including a flange 322. The housing 300 includes a fourth side 324, the fourth side 324 including a reinforcing bead 326. The flange 314 of the second side 313 is connected to the fourth side 324. The flange 312 of the first side 310 is connected to the third side 320. However, after folding and connecting, the hole 340 may remain. Since an airtight seal is required, the excess material on the 2D blank is used to fill the hole 340.

[0096] In some examples, the 2D blank is designed to have excess material at corners, along side surfaces, and / or at other locations to eliminate the bend relief grooves / eyelets at the corners that are typical in press brake bend designs. Fig.11 and Fig.12 , the 2D blank 350 includes a first side 360, a second side 364, and a bottom 366. The 2D blank 350 includes additional material 370, such as rounded corners, and / or other locations, such as edges, including protrusions 372 for filling gaps and preventing holes after folding and connecting.

[0097] In other examples, additional steps are used during manufacturing. In this example, the manufacturing method includes 2D blank design, 2D punching, die bending / folding, ironing and solid state joining, and optional trimming. FIG. 13A to FIG. 13C In FIG. 4 , a 2D blank 404 is planned on a metal plate 400. Fig. 13B 4, 2D blank 404 is removed. In this example, 2D blank 404 includes first side 410, second sides 412 and 414, and bottom surface 406. Second sides 412 and 414 include flanges 416 and 418, respectively, which include complementary shapes that fit together (e.g., along the dashed lines) when folded and connect to form a joint or fusion zone. It will be appreciated that the 2D blank may include a cover or a separate cover may be attached.

[0098] After folding / bending the shell, ironing and in-line solid-state joining are performed to join at least some sides of the shell. During the ironing process, a large contact pressure is applied between the two surfaces to reshape the sides of the shell. In some examples, the large contact pressure generates heat, which causes the metal to flow and then solidify to achieve a solid-state connection. In some examples, the tool performing the ironing is also heated to increase the temperature and promote metal flow and metal agglomeration in the fusion zone.

[0099] In some examples, the connection can be achieved by a butt connection or an overlap connection. If a butt connection is used, the sides of the metal 2D blank are located within a predetermined gap between adjacent sides after bending / folding and before connection. If an overlap connection is used, the sides of the metal 2D blank overlap a predetermined overlap distance after bending / folding and before connection.

[0100] In some examples, if the strength of the fused or joined areas (e.g., along flanges 416 and 418) does not meet design requirements after solid-state joining and / or if solid-state joining cannot be performed at a given location, a secondary joining process (e.g., laser welding) may be used. The secondary joining may be accomplished with or without a specially designed fixture. In some examples, additional features (i.e., offsets) may be added during the final ironing step or post-ironization. Fig. 13C In the embodiment of the present invention, a trimming operation may be optionally performed to remove uneven edges or other material after ironing.

[0101] Reference now FIG. 14A to FIG. 14C , shows an example of a method for manufacturing a housing for a battery cell. Fig.14A In the embodiment of the present invention, at 510, a 2D blank is designed for a 3D housing. The 2D blank is arranged on a metal sheet. In some examples, the metal sheet is coated with an insulating layer. In this example, the 2D blank includes a housing body and a cover. At 514, the 2D blank is cut from the metal sheet. At 518, the 2D blank is bent and / or folded into a housing body. At 522, the housing body and the cover are arranged in a fixture and connected (e.g., using laser welding or another method).

[0102] exist Fig. 14B In the embodiment of the present invention, at 550, a 2D blank is designed for a 3D housing. The 2D blank is arranged on a metal plate. In some examples, the metal plate is coated with an insulating layer. In this example, the 2D blank includes a housing body, and the cover is a separate component. The 2D blank and the cover can be arranged on the same metal plate or on different metal plates. At 554, the 2D blank and the cover are cut from the metal plate. At 558, the 2D blank corresponding to the housing body is bent and / or folded into the housing body. At 560, the housing body is connected. At 564, the housing body and the cover are connected (e.g., using laser welding or another method).

[0103] exist Fig. 14C In the embodiment of the present invention, at 610, a 2D blank is designed for a 3D housing. The 2D blank is arranged on a metal sheet. In some examples, the metal sheet is coated with an insulating layer. In this example, the 2D blank includes a housing body and is designed for subsequent ironing and solid-state connection. At 614, the 2D blank is cut from the metal sheet. At 618, the 2D blank is bent and / or folded into the housing body. At 620, the housing is formed using ironing and solid-state connection. At 624, edge trimming is optionally performed to remove excess material. At 628, the housing body and the cover are connected (e.g., using laser welding or another method).

[0104] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because after studying the drawings, the specification and the appended claims, other modifications will become apparent. It should be understood that one or more steps in the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. In addition, although each embodiment is described as having certain features above, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented in any other embodiment and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the replacement of one or more embodiments with each other is still within the scope of the present disclosure.

[0105] Various terms are used, including "connected," "connected," "coupled," "adjacent," "next to," "on," "above," "below," and "disposed," to describe the spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.). Unless explicitly described as "direct," when a relationship between a first element and a second element is described in the above disclosure, the relationship can be a direct relationship in which there are no other intermediate elements between the first element and the second element, but can also be an indirect relationship in which there are one or more intermediate elements (spatially or functionally) between the first element and the second element. As used herein, the phrase at least one of A, B, and C should be interpreted to mean a logical (A or B or C) using a non-exclusive logical "or", and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

[0106] In the drawings, the direction of the arrows (as indicated by the arrows) generally indicates the flow of information (such as data or instructions) of interest to the diagram. For example, when component A and component B exchange various information, but the information sent from component A to component B is relevant to the diagram, the arrow may point from component A to component B. This unidirectional arrow does not mean that no other information is sent from component B to component A. In addition, for information sent from component A to component B, component B may send a request for the information or a confirmation of receipt of the information to component A.

Claims

1. A method for manufacturing a housing, comprising: designing a two-dimensional (2D) blank corresponding to a three-dimensional (3D) housing body; Planning N 2D blanks on the metal plate, where N is an integer greater than 1; Separating N 2D blanks from the metal sheet; At least one step of bending, folding and creasing one or more edges of the N 2D blanks into a 3D shell body; and Connect multiple edges of the 3D shell body. 2 . The method of claim 1 , further comprising coating the metal plate with an insulating layer.

3. The method of claim 2, wherein the N 2D blanks further comprise a cover, and the method further comprises: Arranging a battery cell stack within the 3D housing body; and The cover is folded to cover the opening of the 3D housing body, and at least one edge of the cover is connected to the opening in the 3D housing body. 4 . The method of claim 3 , wherein the cover includes at least one of a first opening for a terminal and a second opening for a vent.

5. The method according to claim 1, further comprising: After connecting the plurality of edges of the 3D housing body, arranging the battery cell stack in the 3D housing body; and Attach the cover to the opening of the 3D housing body. 6 . The method of claim 5 , wherein the cover is connected to the 3D housing body using at least one of laser welding, crimping, and brazing using a copper welding wire.

7. The method of claim 1, wherein at least one of the plurality of edges of the 3D shell body is ironed and solid-state connected.

8. The method of claim 7, wherein at least one of the plurality of edges of the 3D housing body is laser welded. 9 . The method of claim 1 , wherein at least one of the plurality of edges of the 3D housing body is connected using at least one of laser welding, electron beam welding, brazing using a copper welding wire, and induction welding.

10. The method of claim 1, wherein at least one of the N 2D blanks comprises a first complementary flange portion and a second complementary flange portion, the first complementary flange portion and the second complementary flange portion being aligned, mated and connected after at least one of the bending and forming.

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