Battery Case Corner Geometry to Reduce Rust
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Solution Overview
Problem
Rechargeable batteries experience rust occurrence at the upper end portion due to processing scratches, which can lead to damage and reduced performance.
Innovation Solution
A rechargeable battery design featuring a case with obtuse angles between the front end surface and both the inner and outer surfaces, with nickel plating layers at the corners and an optional rust-preventing chromate film on the front end surface, to minimize rust formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the upper end portion of the case is processed with a punch, then the case can be manufactured, but scratches occur at the inner surface, outer surface, and upper end surface causing rust
Solution Approach 1:
The patent applies preliminary action by forming a rounded corner at the upper end portion of the case before the punching operation. This pre-shaping of the corner radius prevents the punch from creating sharp edges that would otherwise be prone to scratching and subsequent rust during manufacturing processes
Solution Approach 2:
The patent changes the geometric parameter of the case corner from a sharp 90-degree angle to a rounded corner with a specific radius (R1). This parameter change eliminates stress concentration points and prevents scratch formation during punching, thereby preventing rust while maintaining manufacturability
2Ease of manufacture
If the case is processed by cutting with a punch and die, then the case can be formed, but the processing creates scratches that lead to rust
Solution Approach 1:
The patent applies preliminary action by pre-forming rounded corners at the case edges before the cutting operation. This preliminary shaping ensures that when the punch and die cut the case, the blade does not create sharp edges that would scratch the surface and initiate rust
Solution Approach 2:
The patent modifies the geometric parameter of the case edge from a sharp corner to a rounded corner with radius R1. This parameter modification prevents stress concentration and surface scratching during cutting, maintaining both manufacturability and rust resistance
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 effectively reduces rust occurrence by maintaining nickel plating layers on the corners and preventing damage, thereby enhancing the battery's durability and performance.
Implementation Method 1
a plating layer may be formed of nickel to a corner at which the front end surface and the inner surface meet
Implementation Method 2
the film may be a chromate film
Data Source
AI summary
A rechargeable battery that can reduce rust occurrence is provided. The rechargeable battery includes: an electrode assembly including a positive electrode and a negative electrode; a case that houses the electrode assembly; and a cap plate that is coupled to the case, wherein an angle between a front end surface that is formed at the front end of the case and an outer surface of the case is larger than an angle between the front end surface and an inner surface of the case.