Rechargeable Battery Case Structure for Capacity and Insulation
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Solution Overview
Problem
Existing rechargeable batteries face issues with reduced capacity due to the need for space for coupling and insulation between the cell cup and cell tower, and separation under external impact.
Innovation Solution
A rechargeable battery design featuring a case with an upper and lower case partially overlapped and bonded by an insulating material, a cap plate electrically connected to the upper case, and a hook portion for enhanced sealing and fastening, along with insulation members to prevent electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coupling space is provided between cell cup and cell tower, then assembly is enabled, but battery capacity is reduced
Solution Approach 1:
The insulation structure is merged with either the cell cup or cell tower, eliminating the need for separate coupling space. The insulating layer is integrated into the existing housing structure, allowing assembly while maximizing battery capacity by removing dedicated coupling space requirements.
2Reliability
If cell cup and cell tower are separated for insulation, then electrical insulation is achieved, but structural stability deteriorates
Solution Approach 1:
The insulation is applied asymmetrically - the insulating layer is formed on only one component (either cell cup or cell tower) rather than requiring separation between both parts. This asymmetric insulation approach maintains electrical insulation while preserving the symmetric, stable assembly of both housing components.
3Volume of moving object
If coupling space is minimized for ultra-small battery, then size is reduced, but assembly and insulation become difficult
Solution Approach 1:
A thin insulating layer is applied to the housing component, providing necessary electrical insulation without requiring significant space. The thin film approach enables ultra-small battery design while maintaining assembly feasibility and insulation requirements.
4Strength
If hook portion extends inward for fastening, then fastening force is enhanced, but internal space is reduced
Solution Approach 1:
The hook portion is designed with localized inward extension only at the critical fastening point, rather than uniformly reducing internal space throughout. This local quality approach provides enhanced fastening force where needed while minimizing impact on overall internal battery space.
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 maintains battery capacity while ensuring polarity separation and enhanced sealing and fastening, reducing the risk of separation under impact.
Implementation Method 1
The upper case and the cap plate may be heat-bonded through the bonding member.
Data Source
AI summary
A rechargeable battery according to one embodiment of the present invention includes: an electrode assembly having a separator interposed between a first electrode and a second electrode; a case including an upper case having an open lower portion and a penetration hole in the upper portion thereof, and a lower case having an open upper portion to seal the lower portion of the upper case, and accommodating the electrode assembly therein; and a cap plate coupled to the upper case so as to seal the penetration hole and electrically insulated from the upper case, wherein the upper case and the lower case are coupled such that partial regions overlap, and an upper end of the lower case protrudes inwardly and is latched and fixed to the outside of the upper case.