Battery Cup Flange Structure for Swelling Accommodation
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Solution Overview
Problem
Secondary batteries experience swelling during operation, which inefficiently uses available space and can affect mechanical stability and electrode terminal positioning.
Innovation Solution
The battery design includes a flange formed by joining portions of the body and cover cups' sidewalls, extending perpendicular to the reference walls, creating a surplus space to accommodate swelling, and using stainless steel for flexibility and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery case is designed to be compact to maximize energy density, then space utilization is improved, but the electrode assembly has no room to swell during operation
Solution Approach 1:
The battery case is segmented into a body cup and a cover cup that are joined together. The cover cup includes a flange that extends from the body cup, creating a distinct surplus space region. This segmentation allows the main battery compartment to remain compact for high energy density while the flange creates a dedicated swelling accommodation zone without compromising the overall compact design.
Solution Approach 2:
The flange extends in a direction perpendicular to the stacking direction of the electrodes, utilizing a different spatial dimension. This allows the swelling accommodation space to be created in the radial direction rather than consuming axial space, thereby maintaining compact length while providing swelling room through dimensional redirection.
2Stability of the object's composition
If the battery case is designed rigid to maintain mechanical stability, then structural integrity is improved, but the case cannot accommodate swelling of the electrode assembly
Solution Approach 1:
The case is divided into rigid body cup and cover cup portions that maintain overall structural integrity, and a flexible flange portion that can deform to accommodate swelling. This segmentation allows different parts of the case to have different mechanical properties - the main body remains rigid for stability while the flange provides flexibility for swelling accommodation.
Solution Approach 2:
The flange is designed with local quality differences - it has reduced thickness and may include reinforcement ribs that provide localized flexibility while maintaining overall structural support. This allows the flange to deform elastically during swelling while the rest of the case maintains its rigid, stable structure.
3Adaptability or versatility
If the flange extends perpendicular to the reference walls to create surplus space, then swelling accommodation is improved, but the battery length increases
Solution Approach 1:
Instead of extending the flange in the axial direction (perpendicular to reference walls), the flange is designed to extend in the radial direction (parallel to reference walls). This dimensional change allows swelling accommodation space to be created without increasing the battery's length, utilizing the radial space between the electrodes and the case wall.
4Adaptability or versatility
If the sidewalls are joined to form a flange to create free space, then swelling accommodation is improved, but the manufacturing complexity increases
Solution Approach 1:
The case is manufactured as two separate components (body cup and cover cup) that are joined together to form the flange. This segmentation allows each component to be manufactured independently using standard forming processes, and the joining operation creates the flange structure that provides swelling accommodation, balancing manufacturing simplicity with functional complexity.
Solution Approach 2:
The flange is formed by joining the body cup and cover cup sidewalls together. This merging of two simple formed parts creates the complex flange structure that provides swelling accommodation, avoiding the need for complex mold designs or post-manufacturing operations while achieving the desired geometric complexity.
Data Source
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AI summary
A battery (200) may include an electrode assembly (220) including electrodes, and a body cup (210) that includes a first reference wall (212) and a first sidewall (214) provided adjacent to the first reference wall (212), with the body cup (210) having an open end and the body cup (210) accommodating the electrode assembly (220). The battery (200) also includes a cover cup (230) that includes a second reference wall (232) and a second sidewall (234) provided adjacent to the second reference wall (232). The cover cup (230) has an open end and is accommodated in the body cup (210) such that the second reference wall (232) closes the open end of the body cup (210). At least a portion of the first sidewall (214) and at least a portion of the second sidewall (234) are joined to form a flange (240).