Battery Can Structure With Welded Thick Cover for Thin-Wall Precision
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Solution Overview
Problem
Conventional methods for manufacturing battery cans are limited in reducing thickness deviation and cost, with both deep drawing and impact processes being inefficient and costly.
Innovation Solution
A secondary battery design that forms a can with a bottom part, side parts, and a separate cover part, where the cover part has a greater thickness than the other parts, and is coupled through welding, allowing for a thin can with minimal thickness deviation and high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional deep drawing process or impact process is used to manufacture battery can, then manufacturing method is established, but thickness deviation of can is great and manufacturing cost is high
Solution Approach 1:
The can is divided into multiple sections: a bottom wall, a side wall bent from the bottom wall, and a separate cover part. This segmentation allows each part to be manufactured independently with precise thickness control, avoiding the thickness deviation issues of conventional forming processes. The separate cover part can be optimized independently for specific functions such as venting.
Solution Approach 2:
Different parts of the can have different thicknesses according to their specific functional requirements. The cover part has a greater thickness than the bottom part and side parts, providing enhanced protection and venting capability where needed, while maintaining thin walls in other areas to reduce overall weight and cost.
2Weight of moving object
If can thickness is reduced to lower weight and cost, then weight and manufacturing cost decrease, but thickness deviation increases and precision decreases
Solution Approach 1:
By segmenting the can into bottom wall, side wall, and separate cover part, each component can be manufactured as a thin-walled structure with controlled thickness. The separation allows for precise thickness control in each part without the compounding effects seen in conventional forming processes, maintaining precision even as overall thickness is reduced.
Solution Approach 2:
The can structure implements local quality by having different thicknesses in different parts - the cover part has greater thickness for enhanced protection and venting function, while the bottom and side walls are thinner to reduce weight. This localized thickness variation maintains structural integrity and precision while minimizing overall weight.
3Ease of manufacture
If conventional forming processes are used, then can structure is formed, but manufacturing cost remains high due to process limitations
Solution Approach 1:
The can is segmented into a bottom wall, side wall, and separate cover part that can be manufactured using simpler, more cost-effective processes. This segmentation avoids the need for expensive multi-stage deep drawing or impact forming processes, reducing manufacturing cost while maintaining good thickness uniformity in each component.
Solution Approach 2:
The design applies local quality by providing enhanced thickness and protection only where specifically needed (cover part with vent), rather than uniformly thickening the entire can. This allows cost-effective thin-walled construction in most areas while maintaining necessary protection and functionality in critical areas.
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 design enables the production of a thin can with minimal thickness variation and high precision, reducing manufacturing costs and improving efficiency.
Implementation Method 1
Side surfaces of the cover part and outer surfaces of the pair of coupling parts may be welded.
Data Source
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AI summary
A secondary battery includes: an electrode assembly; a can including a bottom part, a pair of side parts integrally formed with the bottom part and bent so as to extend from the bottom part, and a cover part coupled to the pair of side parts to face the bottom part and including a vent, the case accommodating the electrode assembly; and a pair of cap assemblies coupled to open ends of the can to seal the can.