Secondary Battery Cap-Up Thickness Design for Crimping Integrity
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Solution Overview
Problem
Conventional lithium ion secondary batteries face challenges in optimizing the design of the cap assembly, particularly in reducing the terminal portion's thickness to increase operational space while minimizing deformation of the extending portion during the crimping process, which affects the battery's structural integrity and efficiency.
Innovation Solution
The design incorporates a cap-up with a terminal portion of reduced thickness, made from aluminum or aluminum alloy, and an extending portion of greater thickness, formed by press forging, which allows for increased space between the cap-up and safety plate, and reduces deformation during the crimping process, enhancing the battery's structural integrity and gas discharge capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the terminal portion thickness is reduced to increase operational space, then the space between cap-up and safety plate is improved, but the structural strength and resistance to deformation during crimping process deteriorates
Solution Approach 1:
The cap-up is designed with non-uniform thickness distribution: the terminal portion has reduced thickness to create operational space for the safety plate and gas discharge channel, while the extending portion maintains greater thickness to provide structural strength during crimping. This local differentiation of thickness resolves the contradiction between creating space and maintaining strength.
Solution Approach 2:
The thickness parameter of the cap-up is changed spatially - thinner at the terminal portion (less than 3/4 of extending portion thickness) to increase volume/space, and thicker at the extending portion to maintain strength. This parameter variation resolves the contradiction between volume increase and strength maintenance.
2Productivity
If the terminal portion thickness is reduced to provide gas discharge space, then the gas discharge efficiency is improved, but the manufacturing precision and structural integrity deteriorates
Solution Approach 1:
The cap-up implements local quality differentiation with reduced thickness at the terminal portion to create gas discharge space and improve discharge efficiency, while maintaining greater thickness at the extending portion to ensure manufacturing precision and structural integrity during the crimping process.
3Stability of the object's composition
If the extending portion thickness is increased to reduce deformation during crimping, then the structural stability is improved, but the overall device complexity increases
Solution Approach 1:
Rather than uniformly increasing the entire cap-up thickness, the invention applies local quality by concentrating the increased thickness specifically at the extending portion that undergoes crimping. This localized approach improves structural stability during crimping while minimizing overall device complexity.
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
This configuration provides increased operational space for the safety plate and minimizes deformation of the extending portion, improving the battery's structural integrity and gas discharge efficiency, while maintaining a compact form factor.
Implementation Method 1
The cap-up may be press forged to reduce a thickness of the terminal portion
Data Source
AI summary
A secondary battery includes: a cylindrical can; an electrode assembly accommodated in the cylindrical can with an electrolyte; and a cap assembly sealing the cylindrical can. The cap assembly includes a cap-up having a terminal portion, a bent portion downwardly bent from the terminal portion, and an extending portion outwardly extending from the bent portion. The terminal portion has a smaller thickness than the extending portion, and a top-end height of the terminal portion of the cap-up is equal to or less than that of the cylindrical can.