Battery Cell Frame Injection Molding and Sealing

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Solution Overview

Problem

Existing battery cells made of flexible materials often have non-uniform dimensions, which complicates the manufacturing process and affects the durability and appearance of the final product, as they require protection from impact and need to maintain heat radiation while being stacked.

Innovation Solution

A battery cell with a frame made of a thinner, injection-molded material is joined to the circumferential portion of the battery cell, featuring an inserted groove for secure adhesion and a sealing member to fill gaps, ensuring uniform dimensions and improved durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a frame is added to protect the battery cell, then durability and protection are improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

ImprovedurabilityVSAvoidstructure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The frame and battery cell are combined into a single integrated structure where the frame is directly attached to the circumferential portion of the battery cell, creating a unified protective assembly that reduces complexity compared to separate components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The frame is designed with a thin profile that provides protective functionality without adding significant structural complexity or bulk to the battery cell assembly

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If the frame is made thicker for better protection, then durability is improved, but volume and weight increase

Engineering Contradiction:

ImproveprotectionVSAvoidvolume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The frame utilizes a thin-film design that provides adequate protection while minimizing volume occupation, allowing the battery cell to maintain a compact form factor without sacrificing protective capabilities

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The frame thickness parameter is optimized to provide sufficient protection while keeping the overall volume minimal, balancing protective requirements with space constraints

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If separate injection molding is used for the frame, then manufacturing precision is improved, but productivity decreases

Engineering Contradiction:

Improvedimensional accuracyVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The manufacturing process is segmented into separate injection molding of the frame and battery cell, allowing each component to be manufactured with high precision independently, then joined together through a standardized process

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If the battery cell has non-uniform dimensions, then adaptability is improved, but manufacturing precision worsens

Engineering Contradiction:

ImproveflexibilityVSAvoiddimensional consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The frame is designed with local adaptability to accommodate non-uniform dimensions of the battery cell at different locations, while maintaining overall dimensional consistency through the joining structure

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9722221B2Battery cell having frame and method for manufacturing the same

Publication Date: 2017.08.01 SK ON CO LTD

AI summary

Provided are a battery cell for a secondary battery and a method for manufacturing the same, and more particularly, a battery cell having a frame, the frame protecting the battery cell.