Rechargeable Battery Cover Design for Case Thickness Reduction
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Solution Overview
Problem
The existing manufacturing processes for rechargeable batteries often result in case defects and increased thickness due to deep drawing, making it difficult to produce a case that easily accommodates a spirally-wound electrode assembly.
Innovation Solution
A rechargeable battery design featuring a case with a cover that reduces the gap between the opening and the bottom plate, allowing for easier production and insertion of the electrode assembly, and includes a support jaw and welding grooves for enhanced structural integrity and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the case is produced by deep drawing, then the case can be formed with a single manufacturing process, but the case thickness increases and many defects occur
Solution Approach 1:
The case is divided into two separate components: a bottom plate and a cover. The bottom plate is formed by deep drawing while the cover is formed by a different process (such as stamping or forming). This segmentation allows each component to be optimized for its specific manufacturing process, reducing overall thickness and defects while maintaining ease of manufacture.
2Productivity
If the case is produced by deep drawing, then the case can be formed in one step, but the case thickness increases
Solution Approach 1:
The case is segmented into a bottom plate and a cover that are joined together. The bottom plate can be formed by deep drawing in one step for high productivity, while the cover can be made thinner using alternative forming methods. The overall case thickness is reduced while maintaining the productivity benefit of single-step formation for the main component.
3Device complexity
If the case has a standard design without a cover facing the electrode assembly, then the manufacturing process is simple, but the electrode assembly insertion is difficult and gaps between electrodes increase
Solution Approach 1:
The cover is designed with specific local features including a pressing portion that faces the electrode assembly and welding grooves positioned at specific locations. These localized structural modifications improve electrode assembly insertion and reduce electrode gaps without significantly increasing overall device complexity. The cover maintains a relatively simple overall design while having targeted features where needed.
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 facilitates easier production of the case with reduced thickness and improved assembly by minimizing electrode gaps and enhancing bonding strength, thereby simplifying the manufacturing process and ensuring efficient battery assembly.
Implementation Method 1
the case includes a support jaw welded to the first electrode uncoated region
Implementation Method 2
an end portion of the flange and a side end portion of the case may be welded together
Data Source
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AI summary
Embodiments of the present invention provide a rechargeable battery including an electrode assembly including a first electrode and a second electrode. The electrode assembly is spirally-wound.The rechargeable battery also include a case has an opening into which the electrode assembly is inserted, a cover coupled to the case at the opening, and a terminal electrically connected to the second electrode.The terminal extends to the outside of the case. The electrode assembly includes two side surfaces facing opposite directions and two curved surfaces that connect the two side surfaces. A surface of the cover faces a first side surface of the two side surfaces.