Battery Can Welding Structure for Uniform Thin-Wall Cell Cases
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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 inefficient use of space and increased production costs.
Innovation Solution
A secondary battery design that utilizes a can manufactured through blanking, bending, and welding processes, ensuring uniform thickness and reduced thickness deviations by using a metal plate to form a hexahedral shape with specific side portions and welding configurations, such as butt, lap, and overlay joint structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional deep drawing or impact processes are used to manufacture battery cans, then the manufacturing process is established, but the can thickness cannot be reduced and thickness deviation occurs
Solution Approach 1:
The patent changes the manufacturing parameters by switching from deep drawing/impact processes to blanking+bending+welding processes. This parameter change enables precise thickness control (reducing deviation to within 0.01mm) while allowing for thinner can walls, directly resolving the contradiction between thickness uniformity and manufacturing feasibility
Solution Approach 2:
The manufacturing process is segmented into distinct steps: blanking to create the metal plate, bending to form the hexahedral shape, and welding to join edges. This segmentation allows each process to be optimized independently, achieving both precision and ease of manufacture
2Ease of manufacture
If conventional manufacturing processes are used, then the can is produced, but the manufacturing cost is high
Solution Approach 1:
By changing the manufacturing process parameters from conventional deep drawing/impact to blanking+bending+welding, the patent achieves both cost reduction and improved precision. The new process uses simpler equipment and fewer steps while maintaining tight thickness control
Solution Approach 2:
The patent employs a disposable metal plate that is blanked and formed into the can shape. This approach eliminates the need for expensive, complex forming tools and molds required by conventional processes, reducing manufacturing cost while achieving precise thickness uniformity through direct blanking
3Volume of moving object
If the can thickness is reduced to increase capacity, then the battery size is reduced, but thickness deviation increases with conventional processes
Solution Approach 1:
The patent changes the manufacturing approach to blanking+bending+welding, which maintains precise thickness control even when using thinner metal plates. This enables increased battery capacity through reduced can thickness while preventing the thickness deviation that would normally occur with conventional processes
Solution Approach 2:
The metal plate is blanked to the exact final dimensions before bending and welding. This preliminary action ensures that the thickness is precisely controlled from the start, allowing for thinner cans that increase capacity without developing thickness deviations during subsequent forming operations
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 process achieves a thinner can with uniform thickness, allowing for increased capacity and reduced manufacturing costs while preventing welding failures, thus enhancing the battery's charge/discharge capacity and efficiency.
Implementation Method 1
the welding portions may include a first welding portion located between the first short side portion and the second short side portions, and a second welding portion located between the second short side portions
Data Source
AI summary
A secondary battery includes: an electrode assembly; a case accommodating the electrode assembly; and a cap assembly coupled to the case to seal the case, and the case includes a bottom portion, long side portions bent and extended from the bottom portion, a first short side portion bent and extended from the bottom portion, and second short side portions bent and extended from the long side portions, and the first short side portion and the second short side portions are connected to one another to define a short side portion.