Three-Layer Button Battery Housing for Welded Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing button battery housing technologies face challenges with poor sealing performance and machining efficiency due to the use of insulating films and extrusion methods, which lead to leakage and increased manufacturing complexity.
Innovation Solution
A battery housing design featuring a cup-shaped bottom shell and a cover with a three-layer structure, including an outer contact layer, an insulating layer, and an inner contact layer, where the insulating layer is bonded using an anti-electrolyte corrosion material to enhance sealing and prevent water ingress, eliminating the need for an additional insulating film and simplifying the packaging process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating film is provided between the positive housing and negative housing to achieve insulation, then insulation is improved, but the device complexity and machining difficulty increase
Solution Approach 1:
The insulating layer is merged with the cover structure to form an integrated three-layer component (outer contact layer, insulating layer, inner contact layer). This integration eliminates the need for separate insulating films and reduces the number of assembly steps, thereby improving insulation while reducing device complexity
Solution Approach 2:
The insulating layer is pre-formed as part of the cover structure before assembly with the bottom shell. The outer contact layer, insulating layer, and inner contact layer are sequentially formed in advance, allowing for pre-insulation and simplifying the final assembly process
2Reliability
If the positive housing and negative housing extrude the insulating plastic sleeve to complete sealing, then sealing is attempted, but the sealing effect deteriorates and leakage occurs
Solution Approach 1:
The mechanical extrusion sealing method is replaced with a welding-based sealing system. The welding portion of the inner contact layer is welded to the welding support portion of the bottom shell, providing reliable sealing without the deformation and leakage problems associated with extrusion
Solution Approach 2:
The sealing mechanism changes from mechanical pressure (extrusion) to thermal bonding (welding). This parameter change allows for more precise control of the sealing process and eliminates the deformation issues that cause leakage in extrusion-based sealing
3Strength
If the insulating bonding portion has large direct contact area with the inner side of the battery housing, then bonding strength is improved, but electrolyte corrosion and water permeation increase
Solution Approach 1:
The insulating bonding portion is designed with differentiated local qualities: the outer surface has sufficient bonding area for strength, while the inner surface minimizes contact with the battery housing to reduce corrosion. The insulating opening portion creates a localized reduction in contact area where corrosion would occur
Solution Approach 2:
The insulating bonding portion is segmented into different functional zones: areas for bonding to the cover structure and areas that minimize contact with the battery housing. This segmentation allows the bonding strength requirement to be met while reducing the harmful contact area with electrolyte-exposed surfaces
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 solution improves sealing performance, reduces manufacturing complexity, and extends the battery's service life by minimizing electrolyte corrosion and internal water exposure, while maintaining structural stability and firmness.
Implementation Method 1
The insulating bonding portion is configured to be seamlessly bonded to the conductive bonding portion and the welding bonding portion by melting an insulating anti-electrolyte corrosion material at >=100° C.
Implementation Method 2
The insulating anti-electrolyte corrosion material has a thermal shrinkage rate of 6%
Data Source
AI summary
Disclosed are a battery housing and a battery. The battery housing includes a bottom shell and a cover. The cover includes an outer contact layer, an insulating layer, and an inner contact layer. The electrode contact portion of the outer contact layer passes through the insulating layer and the inner contact layer to be electrically connected to one pole of a battery cell. The other electrode of the battery cell can be electrically conducted with the bottom shell. The inner contact layer and the bottom shell are configured to be welded for packaging the battery cell. Since the inner contact layer and the outer contact layer of the cover are pre-insulated, the inner contact layer and the bottom shell need to be welded, and the insulating film is not needed, thereby simplifying the packaging process of the battery and improving the packaging efficiency.