Secondary Battery Case Structure to Prevent Electrode Corner Deformation

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Solution Overview

Problem

Existing secondary battery designs face interference issues between the case and the electrode assembly, particularly at the lower end corner portion, leading to deformation and reduced charging and discharging capacity.

Innovation Solution

A secondary battery case design with an interference prevention portion, such as an interference prevention groove or notch, is implemented to prevent the case from pressing against the lower end corner of the electrode assembly, maintaining the electrode's structural integrity and maximizing power capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the case is designed with a simple structure, then manufacturing cost and complexity are reduced, but the case may interfere with the electrode assembly causing deformation and reduced capacity

Engineering Contradiction:

Improvecase structureVSAvoidelectrode assembly integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The case is designed with uniform wall thickness throughout, eliminating localized thick portions that could interfere with the electrode assembly. This local quality modification prevents deformation while maintaining overall structural integrity and avoiding the need for complex interference prevention features

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of adding complex interference prevention structures to protect the electrode assembly, the invention inverts the approach by designing the case itself with uniform thickness to inherently avoid creating interfering protrusions or thick sections

Inventive Principle:

Principle #13The other way round (Inversion)

2Strength

If the case wall thickness is increased for strength, then structural strength is improved, but interference with the electrode assembly increases causing deformation

Engineering Contradiction:

Improvecase strengthVSAvoidelectrode assembly shape

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The case maintains uniform wall thickness throughout all sections, preventing localized thick portions from interfering with the electrode assembly corners while still providing adequate structural strength through consistent material distribution

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the thickness parameter of the case wall from a variable distribution (with thick portions at corners) to a uniform distribution, which simultaneously maintains strength and prevents interference with the electrode assembly

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20260066399A1Secondary battery and method of manufacturing the same

Publication Date: 2026.03.05 SAMSUNG SDI CO LTD

AI summary

A secondary battery includes a case with an inner space, the case including an opening in an upper end portion thereof and an interference prevention portion at a lower corner thereof, an electrode assembly inside the case, the interference prevention portion being configured to prevent interference between the case and a lower end corner portion of the electrode assembly, and a cap assembly electrically connected to the electrode assembly and coupled to the upper end portion of the case.