Battery Cell Case Structure for Flexible Electrode Assembly Insertion
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Solution Overview
Problem
The assembly of battery cells is challenging due to the need for precise alignment of the electrode assembly with respect to the case openings, leading to increased difficulty and reduced energy density, as existing cases with four closed sides require perpendicular insertion and result in rounded corners that interfere with the electrode assembly.
Innovation Solution
A battery cell design featuring a case with only three wall surfaces, where the two side walls can be inclined outward to form a flaring, allowing flexible electrode assembly insertion and simplifying the assembly process, while also being formed through a simple bending process to reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a case with four closed sides is used, then structural strength is improved, but assembly difficulty increases due to the need for precise perpendicular alignment
Solution Approach 1:
The case is segmented into four wall surfaces (first side wall, second side wall, third side wall, and fourth side wall) that can be independently inclined relative to each other, allowing the electrode assembly to be inserted through openings in any one of these walls without requiring precise perpendicular alignment, thereby reducing assembly difficulty while maintaining structural integrity
Solution Approach 2:
The case structure is designed with dynamic flexibility where the wall surfaces can be inclined outward to form a flaring shape, enabling the openings to accommodate various insertion angles of the electrode assembly, thus simplifying the assembly process while preserving structural strength
2Stability of the object's composition
If four closed side walls are used, then structural integrity is improved, but energy density decreases due to rounded corners interfering with the electrode assembly
Solution Approach 1:
The case is divided into four separate wall surfaces that can be independently positioned and inclined, allowing the openings to be located at positions that do not create rounded corner interference with the electrode assembly, thereby maintaining structural integrity while maximizing the usable volume for energy storage
Solution Approach 2:
The design transitions from a traditional rectangular prism with rounded corners to a structure where wall surfaces can be inclined in different directions, effectively utilizing three-dimensional space more efficiently and eliminating the rounded corner effect that reduces energy density
3Manufacturing precision
If complex machining processes including stretching and aluminum extrusion are used, then case precision is improved, but manufacturing cost increases
Solution Approach 1:
The manufacturing approach changes from complex processes like stretching and aluminum extrusion to a simpler bending process, while the case precision is maintained through the inherent geometric constraints of the four-wall structure that can be independently inclined, thereby reducing manufacturing cost without sacrificing precision
Data Source
AI summary
A battery cell, a battery, an electrical apparatus, and a manufacturing method of a battery cell are provided. The battery cell includes a case, an electrode assembly, an end cover, a first terminal post, and a second terminal post. The case includes two side walls which are perpendicular to a first direction and are spaced apart, and a bottom wall perpendicular to a second direction and connected to the two side walls; the case is provided with a first side opening and a second side opening which are opposite to each other in a third direction, and a top opening opposite to the bottom wall. The electrode assembly is arranged in an accommodating cavity and includes a main body part, and a first tab and a second tab which extend out of the main body part and have opposite polarities. The end cover is connected with the case.