Battery Case Bent Edge Seal Design for Leak Prevention
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Solution Overview
Problem
Conventional secondary battery cases face issues with welding leaks, leading to safety concerns and increased manufacturing costs and time due to complex processes.
Innovation Solution
A case design featuring a body with bent parts and a seal made of materials with lower melting points than the body and bottom, eliminating the need for welding by inserting the bottom into the body and using a seal to prevent moisture and electrolyte leakage, thereby simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join the body and bottom, then the structural strength is improved, but welding leaks occur leading to safety issues and increased manufacturing complexity
Solution Approach 1:
A seal member is introduced as an intermediary component between the body and bottom. This seal member prevents welding leaks by providing a dedicated sealing interface, while the welding process focuses solely on structural joining. The seal member can be made of rubber, plastic, or metal materials that provide reliable sealing without compromising the structural strength of the welded joints.
Solution Approach 2:
The joining system is segmented into two distinct functions: structural joining (achieved through welding) and sealing (achieved through the seal member). This segmentation allows each component to optimize its specific function - the welding provides strong structural connection while the seal member provides leak prevention, eliminating the trade-off between strength and reliability.
2Strength
If welding is used to join the body and bottom, then the structural strength is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The manufacturing process is segmented into independent steps: installing the seal member (which can be done by simple insertion or adhesive bonding) and then welding the body and bottom. This segmentation simplifies each individual step - the seal installation requires no complex equipment, and the welding process becomes more straightforward since it only needs to provide structural joining without worrying about sealing.
Solution Approach 2:
The seal member is installed in advance before the welding process. This preliminary action ensures that sealing is already in place before welding begins, allowing the welding process to focus exclusively on structural joining. This sequence simplifies the overall manufacturing process and reduces the complexity of coordinating multiple functions in a single step.
3Strength
If welding is used to join the body and bottom, then the structural strength is improved, but the manufacturing time and costs increase
Solution Approach 1:
The manufacturing process is divided into independent, parallelizable steps: seal member installation and welding. The seal member can be installed using simple insertion or adhesive bonding methods that are quick and require minimal equipment, while welding proceeds separately to provide structural strength. This segmentation eliminates the need for complex multi-functional welding processes, reducing both time and cost.
Solution Approach 2:
The seal member acts as a mediator that separates the sealing function from the welding process. This allows welding to be performed more efficiently since it only needs to provide structural joining, while sealing is handled by the independently installed seal member. The result is reduced manufacturing time and lower costs while maintaining both structural strength and leak prevention.
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 solution effectively prevents leaks and enhances safety while reducing manufacturing time and costs by eliminating the need for welding, allowing for a more straightforward and cost-effective production of secondary batteries.
Implementation Method 1
a seal disposed in a space between the first bent part of the body and an edge of the bottom
Implementation Method 2
A case design featuring a body with bent parts and a seal made of materials with lower melting points than the body and bottom, eliminating the need for welding by inserting the bottom into the body
Data Source
AI summary
A case for a battery includes a body including at least four side parts and a first bent part at an edge of at least one of the side parts, the four side parts being arranged to define a volumetric structure having two open ends, a bottom coupled to one of the open ends of the body, and a seal disposed in a space between the first bent part of the body and an edge of the bottom.