Battery Casing Structure Without Transition Surfaces
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Solution Overview
Problem
The existing battery casing design, formed as a single unit by a stamping process, results in stress concentration and a transition surface that reduces the usable space and energy density of the battery due to manufacturing limitations.
Innovation Solution
A battery casing design that eliminates the transition surface by directly connecting the casing body to upper and lower covers, which are plate-shaped members, thereby avoiding the formation of a transition surface and enhancing space utilization and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the casing body is formed as a single unit by a stamping process, then the manufacturing process is simple, but a transition surface is formed between the bottom plate and the side plate, reducing the usable space and energy density
Solution Approach 1:
The casing body is divided into separate components: a bottom plate and side plates, which are then connected through welding or other joining methods. This segmentation eliminates the need for a transition surface in the stamping process, thereby maximizing the usable internal space of the battery casing while maintaining manufacturing feasibility through standardized joining processes.
2Stability of the object's composition
If a transition surface is formed between the bottom plate and the side plate, then the single-unit structure is achieved, but the energy density of the battery is decreased due to reduced usable space
Solution Approach 1:
The casing is segmented into a bottom plate and side plates that are joined together, replacing the single-stamped-unit structure. This segmentation eliminates the transition surface that would otherwise reduce internal volume, thereby increasing the space available for active materials and improving energy density while maintaining structural integrity through proper joining techniques.
Solution Approach 2:
The bottom plate and side plates are merged through welding or other joining methods to form a unified casing structure. This merging achieves the structural stability of a single unit while avoiding the space-consuming transition surface, thus resolving the contradiction between structural integrity and energy density.
3Strength
If the casing body includes a transition surface, then the manufacturing process accommodates stress concentration limitations, but the battery dimensions are increased and aesthetics are reduced
Solution Approach 1:
The casing is segmented into separate bottom plate and side plate components, each manufactured independently with optimized geometry that avoids stress concentration issues. The components are then joined together, eliminating the need for a transition surface that would increase overall dimensions and compromise aesthetics.
Solution Approach 2:
A joining method (such as welding) acts as an intermediary between the bottom plate and side plates, allowing direct connection without a transition surface. This intermediary process enables stress management through proper joint design while maintaining compact dimensions and clean aesthetics.
Data Source
AI summary
A battery casing and a battery are disclosed. The battery casing comprises a casing body, an accommodating space being defined in the casing body, the casing body being provided with two open ends, and each open end being in communication with the accommodating space; a lower cover, the lower cover being coupled to one end of the casing body for closing one open end; an upper cover, the upper cover being coupled to the other end of the casing body for closing the other open end, the lower cover and/or the upper cover being a plate-shaped member(s), and side walls of the casing body being perpendicular to the plate-shaped member(s).