Battery Gasket Nesting for Energy Density and Connection Stability
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Solution Overview
Problem
Conventional nonaqueous electrolytic secondary batteries face challenges in achieving high energy density due to the limitations of flat gaskets, which hinder the proximity of the electrode assembly to the battery case's lower surface and are prone to rotation, causing load on electrical connections.
Innovation Solution
A gasket with a contained portion in a recessed package design minimizes projection, enhances electrode assembly occupancy, and includes a rib for insulation, preventing rotation and ensuring secure electrical connections, while reducing material usage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flat gasket is used between the current collector and the battery case, then the structure is simple, but the electrode assembly cannot be disposed sufficiently proximately to the battery case, reducing energy density
Solution Approach 1:
The gasket is nested within a recess formed in the battery case, allowing the gasket to be contained rather than protruding. This nesting arrangement minimizes the space occupied by the gasket and enables the electrode assembly to be disposed closer to the battery case, thereby increasing energy density while maintaining structural simplicity.
Solution Approach 2:
The invention transitions from a flat, two-dimensional gasket arrangement to a three-dimensional configuration where the gasket is positioned within a recess. This dimensional change allows the gasket to be embedded in the battery case structure, reducing the projection height and enabling closer placement of the electrode assembly.
2Ease of manufacture
If a flat gasket is used between the current collector and the battery case, then manufacturing is easy, but the gasket is liable to be rotated, exerting load on the electrical connection
Solution Approach 1:
The gasket is nested within a recess in the battery case, which provides lateral constraints that prevent rotation. The recess walls engage with the gasket edges, securing it in position without requiring complex fastening mechanisms, thus maintaining ease of manufacture while improving connection reliability.
Solution Approach 2:
The recess structure预先 (in advance) prevents the harmful rotation of the gasket by providing geometric constraints before any rotational movement can occur. The recess walls act as preventive barriers that restrict the gasket to a fixed orientation, eliminating the risk of rotation-induced loading on electrical connections.
3Reliability
If the gasket projection from the battery case inner surface is large, then the gasket provides sufficient sealing, but the electrode assembly end cannot be disposed in proximity to the battery case, reducing occupancy
Solution Approach 1:
The gasket is nested within a recess in the battery case, which allows the gasket to provide sealing contact over an extended area without increasing the projection height. The recess accommodates the gasket thickness, enabling sufficient sealing contact between the gasket and both the battery case and current collector while keeping the overall projection minimal.
Solution Approach 2:
The gasket sealing function is segmented into two contact surfaces: one contact surface with the battery case inner surface and another contact surface with the current collector. This segmentation allows the gasket to provide sealing at both interfaces while being contained within the recess, achieving adequate sealing without excessive projection.
Data Source
AI summary
A battery includes a cover (4) for sealing an opening of a battery case (12) which contains an electrode assembly (3) therein and current collectors (12) for electrically connecting external terminals (14,15) whose at least parts are disposed outside of the cover to the electrode assembly, respectively. Gaskets (17) are interposed between a lower surface of the cover (4) and the current collectors (12), respectively. In the gasket (17), a caulked portion is contained in an engagement recess formed at the lower surface of the cover (4). In contrast, the entire gasket (17) is contained in another engagement recess formed at the lower surface.