Secondary Battery Resin Molding Unit Eliminates Lower Case
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Solution Overview
Problem
The manufacturing process of lithium ion secondary batteries is time-consuming due to the separate steps of attaching a label and forming the lower case, which can be optimized for a more streamlined production.
Innovation Solution
A secondary battery design that integrates a protective circuit module, an upper case, a protective film, and a resin molding unit, where the resin molding unit is formed in the upper case and on the sides and bottom surface of the bare cell, eliminating the need for a separate lower case and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the label attachment and lower case formation are performed separately in the second part of manufacturing, then each component can be formed with proper quality, but the manufacturing time increases
Solution Approach 1:
The patent combines the label and lower case into a single integrated component that is formed in one molding process. The label is pre-formed with adhesive layers, then both the label and lower case are molded simultaneously as one piece, eliminating the need for separate attachment steps while maintaining quality standards for both components.
Solution Approach 2:
The label is pre-formed with adhesive layers applied before the final assembly step. This preliminary preparation of the label with adhesive allows it to be integrated with the lower case in a single subsequent molding operation, rather than requiring separate adhesive application and attachment steps after both components are formed.
2Reliability
If multiple separate manufacturing steps are used for assembling the battery components, then each component can be properly assembled, but the overall device complexity increases
Solution Approach 1:
The patent merges multiple assembly operations into a single integrated molding process. The label, lower case, and their interconnection are formed in one continuous operation, reducing the number of discrete assembly steps and interfaces that could potentially fail, while maintaining proper component alignment and connection.
Solution Approach 2:
The molding process is designed to perform multiple functions simultaneously: forming the lower case structure, attaching the label with adhesive, and creating the integrated assembly all in one operation. This multi-functional approach reduces process complexity while ensuring proper assembly quality.
Data Source
AI summary
A secondary battery and a method of manufacturing the same, the secondary battery including a bare cell for charging and discharging electricity; a protective circuit module for protecting the bare cell; an upper case, the upper case being coupled to the protective circuit module and disposed at an upper part of the bare cell; a protective film surrounding an external surface of the bare cell; and a resin molding unit disposed in the protective film, in the upper case, and in a lower part and on a bottom surface of the bare cell.