Sealed Battery Flange Joint Design
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Solution Overview
Problem
The existing sealed storage battery design with a flange portion joining metal sheets reduces total energy density and increases the risk of short circuits, while also being inefficient in production.
Innovation Solution
A sealed storage battery design where the flange portion of a first metal sheet is joined to a second metal sheet with a hot-melt resin, and both sheets are folded back toward a recessed portion, with the flange portion's outer edge protruding relative to the second metal sheet's edge, eliminating the need for a metal terminal and enhancing energy density and reducing short circuit risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flange portion is used to join the two metal sheets, then the structural integrity and ease of manufacture are improved, but the total energy density decreases due to the increased volume occupied by the joining structure
Solution Approach 1:
The invention extracts the metal terminal from the battery structure, eliminating the need for separate terminal components. The flange portion itself serves dual functions as both the joining structure and the positive electrode, thereby removing unnecessary material that would reduce energy density while maintaining structural integrity and ease of manufacture.
Solution Approach 2:
The invention merges the flange portion and the positive electrode into a single integrated component. The flange portion of the first metal sheet serves as both the structural joining element and the active positive electrode, eliminating the need for separate terminal structures and improving total energy density while maintaining ease of manufacture.
2Stability of the object's composition
If the flange portion is used to join the two metal sheets, then the structural integrity is improved, but the short circuit risk increases due to the proximity of conductive parts
Solution Approach 1:
The invention introduces a non-conductive adhesive layer as an intermediary between the flange portion (positive electrode) and the second metal sheet (housing/negative electrode). This adhesive layer maintains the structural integrity provided by the flange portion joining while electrically isolating the conductive parts, thereby reducing short circuit risk.
Solution Approach 2:
The invention applies different material properties to different parts of the joining structure. The flange portion itself remains conductive to maintain electrical function, while the adhesive layer providing the joining function is non-conductive to prevent short circuits. This local differentiation of material properties resolves the contradiction between structural integrity and short circuit prevention.
3Productivity
If the metal terminal protruding from the housing is used, then the electrical connection is simplified, but the production efficiency decreases and the short circuit risk increases
Solution Approach 1:
The invention extracts the protruding metal terminal from the battery structure, eliminating the need for separate terminal components and their associated assembly steps. This simplifies the overall structure, improves production efficiency by reducing assembly complexity, and reduces short circuit risk by removing exposed conductive elements that could contact the housing.
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
This design improves total energy density and reduces the risk of short circuits, making the battery easier to produce and safer, with the folded joint and protruding edge configuration enhancing both energy storage and safety.
Implementation Method 1
The flange portion is joined to the second metal sheet with a hot-melt resin
Data Source
AI summary
A sealed storage battery that is easy to produce, has a low short circuit risk, and has an improved total energy density is provided. A battery includes a first metal sheet having a recessed portion, the recessed portion having a flange portion at its periphery, a multilayer electrode assembly housed in the recessed portion, and a second metal sheet covering the flange portion and the recessed portion. The first metal sheet and the second metal sheet also serve as electrodes. The flange portion is joined to the second metal sheet with a hot-melt resin. A joint between the flange portion and the second metal sheet is folded back toward the recessed portion. An outer edge of the flange portion folded back toward the recessed portion protrudes relative to an outer edge of the second metal sheet folded back toward the recessed portion.