Closed Battery Housing Profile With Integrated Rupture Venting

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Solution Overview

Problem

Existing methods for manufacturing sealed housings for electrical cells with overpressure valves are costly due to the installation of separate valves and additional process steps, which can lead to increased production costs.

Innovation Solution

A profiling system that integrates an overpressure valve by embossing a predetermined rupture point into a metal band, which bursts at a specific pressure to vent gas, and continuously forms a closed profile using a series of devices including an embossing, punching, joining, and cutting process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate overpressure valve is installed into the housing, then the housing can discharge gas when pressure exceeds threshold, but additional costs and process steps are associated with installation

Engineering Contradiction:

Improvegas discharge capabilityVSAvoidinstallation process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The overpressure valve function is merged directly into the profile structure by forming an integrated rupture point during the roll-forming process. The profile itself becomes the pressure-containing element with an embedded weak point, eliminating the need for separate valve components and their installation steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rupture point is pre-formed into the profile during manufacturing at a predetermined location with reduced thickness. This preliminary action ensures that when overpressure occurs, the rupture point will fail at the intended location to discharge gas, eliminating the need for separate valve installation while maintaining reliability.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a separate overpressure valve is installed into the housing, then the housing can discharge gas when pressure exceeds threshold, but additional manufacturing costs are incurred

Engineering Contradiction:

Improvegas discharge capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The profile structure provides its own overpressure protection function through the integrated rupture point. The profile serves dual purposes: structural containment and pressure relief, eliminating the need for separate valve components and their installation steps.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If the profile is made with uniform thickness, then manufacturing is simpler, but no predetermined rupture point can be created for forced venting

Engineering Contradiction:

Improveprofile manufacturingVSAvoidoverpressure protection

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The profile has non-uniform thickness with a localized reduced-thickness region at the predetermined rupture point. This local quality change creates the weak point necessary for controlled rupture while maintaining overall profile strength for pressure containment, resolving the contradiction between manufacturing simplicity and overpressure protection.

Inventive Principle:

Principle #3Local quality

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

This method reduces manufacturing costs and time by integrating the overpressure valve within the profiling process, allowing for efficient and cost-effective production of sealed housings with integrated venting capabilities.

Implementation Method 1

a predetermined rupture point is embossed into a rupture metal band by the embossing device for forced venting at a burst pressure. At the predetermined rupture point, a thickness of the rupture metal band is smaller than a thickness of the rupture metal band outside the predetermined rupture point, so that the rupture metal band is mechanically weakened at the predetermined rupture point

Methodology Applied

Scientific EffectMechanical deformation: Deformation

Implementation Method 2

the profile metal band and the rupture metal band are joined by material-bonding on top of one another by the second joining device, so that the predetermined rupture point and the opening in the profile metal band fit each other

Methodology Applied

Scientific EffectMaterial bonding: Welding

Implementation Method 3

the profile metal band is roll-formed into a profile by the profiling device

Methodology Applied

Scientific EffectRoll-forming: Deformation

Data Source

PatentUS20250391961A1Method for a profiling system, closed profile according to the method, and housing with the closed profile

Publication Date: 2025.12.25 FISCHER EDELSTAHLROHRE

AI summary

A method for producing a closed profile for a sealed housing for an electrical cell, the method configured to be performed by a profiling system including a profiling device, a first joining device, an embossing device, and a separating device, the method including the profiling system continuously performing steps including: roll-forming, by the profiling device, a profile metal band having a first band edge and a second band edge into a profile; material-bonded joining, by the first joining device, of the first band edge and the second band edge of the roll-formed profile to one another, whereby the profile is closed; embossing, by the embossing device, a predetermined rupture location into the profile metal band for forced venting at a bursting pressure; and cutting, by the separating device, the previously closed profile to a length, thereby producing the closed profile.