Battery Case Weight Reduction via Partial Metal Cladding
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Solution Overview
Problem
The challenge is to create a battery casing that utilizes low-density materials like aluminum while maintaining hermetic sealing and withstanding high temperatures required for feedthrough assembly attachment, as conventional methods often damage these materials.
Innovation Solution
A battery case design where a second metal is clad with a third metal, allowing the use of low-density materials for the casing and feedthrough assembly, with the third metal covering less than 90% of the second metal's surface to reduce weight and withstand attachment temperatures, using metal cladding processes to form a hermetic seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum or other low density materials are used for the battery casing, then the weight of the battery is reduced, but the casing cannot withstand the high temperatures required for hermetically attaching the feedthrough assembly
Solution Approach 1:
The battery casing is constructed as a composite structure with an inner aluminum casing providing low weight and an outer stainless steel casing providing high temperature resistance. The two metal casings are hermetically joined together, allowing the aluminum component to reduce overall weight while the stainless steel component withstands the high temperatures required for feedthrough assembly attachment without melting or deforming.
2Quantity of substance
If aluminum is used for the battery casing, then the density and weight are reduced, but the hermetic sealing capability at high temperatures is compromised
Solution Approach 1:
The patent employs a composite casing structure where aluminum provides low density and stainless steel provides high temperature hermetic sealing capability. The hermetic joint between the aluminum inner casing and stainless steel outer casing maintains sealing reliability at high temperatures while preserving the weight advantages of aluminum.
3Temperature
If conventional metal cladding is applied to the entire battery casing, then high temperature resistance is achieved, but the weight reduction benefit of using aluminum is significantly compromised
Solution Approach 1:
Instead of applying high temperature resistant material to the entire casing, the patent uses stainless steel only for the outer casing and hermetic joint areas where high temperature resistance is actually needed. The majority of the casing structure remains aluminum, providing weight reduction while the localized stainless steel portions provide necessary temperature resistance at critical locations.
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 approach enables the use of low-density, low-cost materials for the battery casing, reducing weight and cost while maintaining a hermetic seal and withstanding high temperatures during feedthrough assembly attachment.
Implementation Method 1
The second metal is clad with a third metal such that the third metal covers less than 90% of an upper surface of the second metal... withstanding high temperatures during feedthrough assembly attachment
Implementation Method 2
forming a cover from the metal sheet... bonding a feedthrough assembly to the third metal on the cover... The metal cladding process can be an inlay type metal cladding process
Data Source
AI summary
A battery case is disclosed. The case includes a cover bonded to a body such that a bottom of the cover and the body define at least a portion of the interior of a battery. The cover includes a second metal which is bonded to a first metal included in the battery body. The second metal is clad with a third metal such that the third metal covers less than 90% of an upper surface of the second metal. A hole extends through the second metal and the third metal. The case also includes a feedthrough assembly extending through the hole. The feedthrough assembly includes a feedthrough pin surrounded by a feedthrough body. The feedthrough body includes a fourth metal bonded to the third metal in the cover.