Prismatic Battery Casing Butt-Weld Layout for Hermetic Sealing
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Solution Overview
Problem
Existing deep drawing and extrusion processes for forming battery casings are limited by dimension constraints and require expensive tooling, making it challenging to achieve hermetic sealing without these drawbacks.
Innovation Solution
A battery casing design that includes a first portion with a planar portion and extending top or bottom portions, and a second portion with planar and side portions, forming a prism. This design is configured to be welded together using butt joints, allowing for hermetic sealing without the limitations of deep drawing or extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deep drawing or extrusion process is used to form battery casing, then hermetic sealing is achieved, but expensive tooling is required and dimensional flexibility is limited
Solution Approach 1:
The battery casing is divided into multiple separate components (first portion with top/bottom portions and first planar portion, second portion with second planar portion and side portions) that are manufactured independently and then joined through welding. This segmentation eliminates the need for expensive deep drawing or extrusion tooling while maintaining hermetic sealing capability through welded joints.
2Reliability
If deep drawing or extrusion process is used to form battery casing, then hermetic sealing is achieved, but dimensional constraints (thickness, depth) are imposed
Solution Approach 1:
By segmenting the casing into multiple weldable portions, the design achieves dimensional flexibility that is not possible with monolithic deep drawing or extrusion processes. Each portion can be independently formed with different thicknesses and geometries, allowing optimization for specific dimensional requirements while maintaining hermetic sealing through welding.
Solution Approach 2:
The invention changes the manufacturing approach from form-intensive processes (deep drawing, extrusion) to welding-intensive processes, allowing independent variation of dimensional parameters (thickness, depth, shape) for each casing portion without being constrained by tooling limitations.
3Reliability
If multiple butt joints are used to assemble battery casing portions, then hermetic sealing is achieved, but welding process complexity increases
Solution Approach 1:
Instead of using complex sealing mechanisms or gaskets to achieve hermetic sealing, the invention inverts the approach by using simple butt welds on planar surfaces. The hermetic sealing is achieved through the inherent integrity of welded joints rather than additional sealing components, simplifying the overall manufacturing process.
Solution Approach 2:
The invention uses uniform butt joint welding across all connections between casing portions, creating a homogeneous welding process that simplifies manufacturing. All joints use the same welding technique and parameters, reducing process complexity compared to using different joining methods for different portions.
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 proposed battery casing design enables hermetic sealing while offering flexibility in size and shape, reducing the need for expensive tooling and overcoming the dimensional limitations of traditional processes.
Implementation Method 1
The first portion and the second portion are configured to be welded together at (i) a first butt joint extending along the first side portion to join the first side portion to the first planar portion and to one of the top portion and the bottom portion at the first side portion
Data Source
AI summary
A battery casing includes a first portion including a first planar portion and a bottom portion and a second portion having a second planar portion, a first side portion, and a second side portion, the first portion and the second portion configured to be welded together at (i) a first butt joint extending along the first side portion to join the first side portion to the first planar portion and to the bottom portion at the first side portion, (ii) a second butt joint extending along the second planar portion to join the second planar portion to the bottom portion at the second planar portion, and (iii) a third butt joint extending along the second side portion to join the second side portion to the first planar portion and to the bottom portion at the second side portion.