Battery Can Structure With Bent-Welded Thin Walls

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Solution Overview

Problem

Conventional battery can manufacturing processes, such as deep drawing and impact processes, are limited in reducing can thickness and result in thickness deviations and high manufacturing costs, leading to inefficiencies in battery capacity and production costs.

Innovation Solution

A secondary battery design that utilizes a can made by bending and welding a metal plate to form a hexahedral shape with uniform thickness, featuring long and short side portions connected by welding, allowing for reduced thickness and improved dimensional accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional deep drawing or impact process is used to manufacture battery can, then manufacturing process is established, but can thickness cannot be reduced and thickness deviation occurs

Engineering Contradiction:

Improvecan thickness uniformityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the manufacturing parameters by transitioning from deep drawing/impact processes to a bending-welding process using a metal plate. This allows for reduced can thickness (0.1-0.5mm) while maintaining uniform thickness throughout the can structure, eliminating the thickness deviation inherent in conventional processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the conventional deep drawing or impact mechanical forming processes with a bending and welding mechanical system. The metal plate is bent into the can shape and then welded at the joints, substituting the stamping-based mechanical system with a forming-welding system that achieves better thickness control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional deep drawing or impact process is used to manufacture battery can, then can structure is formed, but manufacturing cost is high

Engineering Contradiction:

Improvemanufacturing costVSAvoidcan thickness uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent changes the manufacturing approach to use a bending-welding process with thinner metal plates (0.1-0.5mm), reducing material cost and manufacturing complexity while achieving uniform thickness. This parameter change eliminates the need for expensive multi-step deep drawing or impact processes.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If can thickness is reduced to increase battery capacity, then battery capacity relative to size increases, but thickness deviation and manufacturing difficulty increase

Engineering Contradiction:

Improvebattery capacityVSAvoidcan thickness uniformity

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent implements parameter changes by using a bending-welding manufacturing process that maintains uniform thickness even when using thin metal plates (0.1-0.5mm). This enables reduced can thickness to increase battery capacity while avoiding the thickness deviation that would normally occur with thinner materials in conventional processes.

Inventive Principle:

Principle #35Parameter changes

4Volume of moving object

If can thickness is reduced to minimize can size, then battery size is reduced, but manufacturing precision and dimensional accuracy deteriorate

Engineering Contradiction:

Improvebattery sizeVSAvoiddimensional accuracy

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent replaces the conventional stamping-based mechanical forming system with a bending-welding mechanical system. This substitution enables precise dimensional control and uniform thickness in miniaturized cans, as the bending process allows for better control of thin metal plate deformation at small scales.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 new manufacturing method results in a can with uniform thickness and reduced manufacturing costs, increasing battery capacity while maintaining the same size as conventional batteries, and preventing welding failures during assembly.

Implementation Method 1

a case made of metal and accommodating the electrode assembly, wherein the case includes a bottom portion, long side portions bent and extended from the bottom portion

Methodology Applied

Scientific EffectBending: Deformation

Implementation Method 2

first short side portions connected to one another only at the respective short side to define a short side portion

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP3690975B1Secondary battery

Publication Date: 2025.10.15 SAMSUNG SDI CO LTD

Figure 1
Figure 2A
Figure 2B

AI summary

A secondary battery includes: an electrode assembly (110); a case (140) accommodating the electrode assembly (110); and a cap assembly coupled to the case (140) to seal the case (140), and the case (140) includes a bottom portion (141), long side portions (142, 143) bent and extended from the bottom portion (141), a first short side portion (144a) bent and extended from the bottom portion (141), and second short side portions (144b, 144c) bent and extended from the long side portions (142, 143), and the first short side portion (144a) and the second short side portions (144b, 144c) are connected to one another to define a short side portion (144).