Battery Housing Weld Flange Reduction for Higher Cell Volume
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Solution Overview
Problem
The interior volume of battery housings is limited by the presence of a flange, which reduces the volumetric energy density and the amount of power that can be provided to electronic devices, as the flange occupies space within the device and limits the size of the battery.
Innovation Solution
A battery housing design with a reduced flange length, achieved by welding a can and a cover to form a cavity with a curved and planar portion, where the weld seam begins at the end of the planar portion adjacent to the curved portion, and the flange is cut along or adjacent to the weld seam, resulting in a flange length of 300 microns or less, thereby increasing the interior volume and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flange is included in the battery housing to facilitate manufacturing and component coupling, then ease of manufacture is improved, but the interior volume of the housing is reduced
Solution Approach 1:
The patent applies parameter changes by reducing the flange length from conventional dimensions to 300 microns or less. This quantitative modification allows the flange to maintain its manufacturing facilitation function while occupying minimal space, thereby resolving the contradiction between ease of manufacture and interior volume.
Solution Approach 2:
The patent applies local quality by concentrating the flange function at a specific location (the outermost end of the can) with a minimized footprint. The curved portion and planar portion are strategically positioned to provide coupling capability only where needed, while the rest of the housing maximizes interior volume for electrode material.
2Ease of manufacture
If a flange is included in the battery housing to facilitate component coupling, then manufacturing functionality is improved, but the volumetric energy density is reduced
Solution Approach 1:
The patent applies parameter changes by modifying the flange length parameter to 300 microns or less. This quantitative adjustment ensures that the flange provides sufficient coupling functionality for manufacturing while minimizing the volume it occupies, thereby maximizing the volume available for electrode material and improving volumetric energy density.
Solution Approach 2:
The patent applies the extraction principle by separating the flange function from the main housing body. The flange is formed as a distinct feature (curved portion and planar portion) that can be precisely controlled and minimized, allowing the housing to provide both manufacturing functionality and maximum energy storage capacity.
3Volume of stationary object
If the flange length is reduced to increase interior volume, then the interior volume and energy density are improved, but the hermetic seal integrity may be compromised
Solution Approach 1:
The patent applies parameter changes by precisely controlling the flange length to 300 microns or less while maintaining the hermetic seal through the weld seam configuration. The curved portion and planar portion are designed to ensure proper sealing even at this reduced dimension, resolving the contradiction between maximizing interior volume and maintaining seal integrity.
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 reduced flange length increases the interior volume of the battery housing, enhancing the volumetric energy density and power capacity of the battery, while maintaining a hermetic seal.
Implementation Method 1
The planar portion is coupled to the cover via a weld seam to form a flange
Data Source
AI summary
A housing of a battery may be produced to have a reduced flange, such that an interior volume of the housing is increased. The housing may include a can and a cover welded to one another to form a flange of the housing. The cover may be generally planar, and the can may include a curved portion and a planar portion extending from the curved portion. The planar portion may be welded to the cover to form the flange. A weld seam between the can and the cover may begin generally at an end of the planar portion of the can adjacent to the curved portion, and the flange may be cut along or adjacent to the weld seam. In particular, a distance between a transition point of the curved portion of the can and an outermost end of the flange may be less than 300 microns.