Insulating Cell Case Recesses to Cut Battery Electrolyte Volume
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Solution Overview
Problem
The manufacturing cost of secondary batteries is high due to the need for a large amount of electrolyte solution to fully soak the bare cell, which is accommodated in a cell case with dimensions greater than the bare cell, leading to inefficiencies and increased production costs.
Innovation Solution
A secondary battery design featuring a cell case with recesses at its boundary positions, made of insulating materials like plastic or ceramic, which reduces the volume and capacity of the cell case, allowing for a smaller amount of electrolyte solution to be used, and includes an end cover assembly with an insulating cell lid and electrode post for connection and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cell case dimensions are made larger to accommodate the bare cell with sufficient electrolyte solution, then the bare cell can be fully soaked and operate normally, but the volume of the cell case increases leading to higher manufacturing cost
Solution Approach 1:
The cell case is designed with non-uniform wall thickness, featuring thicker walls at the bottom and thinner walls at the top. This local variation in quality allows the cell case to provide sufficient electrolyte solution volume for bare cell operation while minimizing overall volume and reducing manufacturing cost.
Solution Approach 2:
The invention changes the geometric parameters of the cell case by introducing specific wall thickness variations and dimensional ratios (L/W≥7 or H/L≥3). These parameter changes optimize the balance between providing adequate electrolyte solution volume and minimizing cell case volume to reduce cost.
2Reliability
If the cell case is made of insulating material to prevent short circuit, then the reliability improves, but the manufacturing complexity increases
Solution Approach 1:
The cell case is made of insulating material such as plastic or ceramic instead of conductive materials. This material selection provides electrical insulation to prevent short circuits between the cell and cell case, improving reliability while the simple structural design keeps manufacturing complexity manageable.
3Reliability
If more electrolyte solution is injected to fully soak the bare cell, then the cell can operate normally, but the manufacturing cost increases
Solution Approach 1:
The non-uniform wall thickness design (thicker bottom, thinner top) creates local variations in electrolyte solution distribution. This allows the electrolyte solution to be concentrated where it is most needed for cell operation while reducing the total amount required, thus lowering manufacturing cost while maintaining full soaking.
Data Source
AI summary
Secondary battery, battery pack, and energy storage container are provided. Secondary battery includes bare cell, end cover assembly, and cell case. End cover assembly includes cell lid, electrode post, and connecting plate. Cell lid has mounting hole. Electrode post passes through mounting hole and is mounted on cell lid. Connecting plate connects electrode post and bare cell. Cell lid is made of insulating material. Cell is mounted inside cell case. Cell case is made of insulating material. Cell case has recess which is located at boundary position of cell case and recessed in direction adjacent to bare cell. End cover assembly covers cell case. Recess can reduce distance between inner wall of cell case and cell and volume of gap. Recess arranged in cell case reduces volume and capacity of cell case, reduces an amount of an electrolyte solution required to be injected, and reduces processing and manufacturing costs.