Secondary Battery Central Structure for Welding-Free Case Assembly
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Solution Overview
Problem
Secondary batteries using stainless steel cases are prone to deformation, breakage, and internal damage during welding, limiting volume utilization and energy density due to flange portions and welding risks.
Innovation Solution
A secondary battery design featuring a central structure with grooves for case coupling and an internal cavity, eliminating welding and cutting processes, and using adhesive materials for fixation, along with insulating layers and conductive terminals to enhance rigidity and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stainless steel cases are used to increase rigidity and protect against deformation, then strength and protection are improved, but welding processes cause internal damage and reduce reliability
Solution Approach 1:
The battery case is divided into multiple segments (first case, second case, and central structure) that are coupled together without welding. Each segment can be independently formed and assembled, eliminating the need for welding processes that could damage the electrode assembly while maintaining overall structural strength.
Solution Approach 2:
A central structure acts as an intermediary component between the first case and second case. This central structure includes coupling grooves that receive the case halves and provide a welding-free connection interface, protecting the electrode assembly from welding damage while maintaining case rigidity.
2Strength
If four-side welding and cutting processes are used to assemble stainless steel cases, then case strength is improved, but flange portions remain that increase volume and reduce space utilization
Solution Approach 1:
The case is segmented into modular components (first case, second case, central structure) that connect through coupling grooves. This segmentation eliminates the need for traditional four-side welding and cutting, removing flange portions and reducing overall battery volume while maintaining assembly strength.
Solution Approach 2:
The harmful flange portions are completely removed by extracting the welding and cutting processes from the manufacturing method. The cases are designed with coupling grooves that enable direct assembly without generating waste flange material, maximizing internal volume.
3Quantity of substance
If thin membrane outer portions are used to increase energy density, then energy density is improved, but the membrane is easily deformed and broken under physical impact
Solution Approach 1:
The battery employs a composite case structure combining stainless steel segments (first case, second case) with a central structure. This composite design provides the rigidity and impact resistance of metal while accommodating the thin membrane inner structure needed for high energy density, protecting it from external physical impact.
4Strength
If welding processes are used to assemble stainless steel cases, then case strength is improved, but the process is complex and time-consuming
Solution Approach 1:
The case is designed as segmented modular components that connect through simple coupling grooves rather than requiring complex welding procedures. This segmentation enables faster assembly through mechanical coupling, improving manufacturing efficiency while maintaining structural strength.
Solution Approach 2:
The welding process is replaced with a mechanical coupling system using grooves and fitting interfaces. This substitution eliminates the complexity and time requirements of welding operations while maintaining case strength through precise mechanical interlocking.
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 design minimizes damage risks, maximizes internal space, and increases energy density by removing flange portions and ensuring a rigid exterior, while maintaining electrical connectivity.
Implementation Method 1
an adhesive material may be on the first groove and the second groove such that the central structure and the first case are fixedly coupled to each other and the central structure and the second case are fixedly coupled to each other
Data Source
AI summary
A secondary battery includes an electrode assembly including a first electrode, a separator, and a second electrode stacked sequentially, a first case configured to accommodate a portion of the electrode assembly, a second case configured to accommodate another portion of the electrode assembly, and a central structure between the first case and the second case.