Battery Casing Seal with Void Volume and Formable Layer

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Solution Overview

Problem

Conventional small batteries, such as button batteries, face challenges in optimizing energy density due to bulky designs caused by the need for separate sealing elements and electrode separations, which occupy valuable space and are costly to produce.

Innovation Solution

A battery cell casing with a first and second contact surface, where an electrically insulating void volume layer and a formable material layer combine to form a gas-tight and electrically insulating seal, eliminating the need for additional sealing elements and allowing for a compact, cost-efficient design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate sealing elements (rubber or plastic rings) are used between cup and cover, then gas-tight sealing is achieved, but battery size increases and energy density decreases

Engineering Contradiction:

Improvegas-tight sealingVSAvoidbattery size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The sealing function is merged with the contact surface between casing elements. The seal layer is formed by an electrically insulating void volume layer on one contact surface and a formable material layer on the other contact surface, eliminating the need for separate rubber or plastic sealing rings. This integration reduces battery volume while maintaining gas-tight sealing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The formable material layer acts as a thin, flexible sealing film that deforms under pressure to fill voids on the void volume layer surface. This thin film approach replaces bulky rubber rings, achieving gas-tight sealing with minimal space occupation.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If separate sealing elements and electrode separations are used, then reliable sealing and electrode isolation are achieved, but production cost increases

Engineering Contradiction:

Improvesealing reliabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Multiple functions (sealing, electrical insulation, and contact surface formation) are merged into a single integrated seal layer structure consisting of the void volume layer and formable material layer. This reduces the number of separate components and assembly steps, thereby lowering production cost while maintaining sealing reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The seal layer uses a composite structure combining an electrically insulating void volume layer (e.g., porous ceramic material) with a formable material layer. This composite material approach provides both sealing and electrical insulation properties in one integrated layer, simplifying manufacturing compared to assembling multiple separate components.

Inventive Principle:

Principle #40Composite materials

3Reliability

If conventional sealing structures are used, then gas-tight connection is achieved, but available space for active materials is reduced

Engineering Contradiction:

Improvegas-tight connectionVSAvoidactive material space

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The seal layer is formed by very thin layers (void volume layer and formable material layer) that combine to provide gas-tight sealing. These thin films occupy minimal space compared to conventional bulky sealing elements, maximizing the volume available for active materials while ensuring reliable gas-tight connection.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing function is integrated directly into the contact surfaces between casing elements, eliminating the need for additional space-consuming sealing components. This integration ensures that the minimum necessary space is used for sealing, leaving maximum volume for active materials.

Inventive Principle:

Principle #5Merging (Combining)

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 solution enables a compact battery size with improved energy capacity and simplified production, ensuring a reliable gas-tight connection without additional space for sealing elements, suitable for ultra-compact battery applications.

Implementation Method 1

the formable material layer fills voids on a surface of the void volume layer hermetically... the formable material of the formable material layer deforms into the voids on the void volume layer

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS8697278B2Battery cell casing with seal

Publication Date: 2014.04.15 WYON PATENT AG

AI summary

A battery cell casing comprises a first casing element (1) with a first contact surface (7) and a second casing element (2) with a second contact surface (8). In an assembled position the first and second contact surfaces (7, 8) contact each other and the first and second casing elements (1, 2) encase active materials (9, 10) of a battery cell in an interior space. At least one seal layer is arranged between the first and second contact surfaces (7, 8) to seal the interior space, wherein one of first and second contact surface (7; 8) comprises a void volume layer and the other of first and second contact surface (7; 8) comprises a formable material layer, which fills voids on a surface of the void volume layer hermetically in the assembled position and forms the seal layer.