Curved Battery Shell Segmentation for Assembly
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Solution Overview
Problem
Existing curved batteries face difficulties in electrode assembly welding, electrode assembly contact, and accommodating special-shaped electrode assemblies within a curved shell, leading to manufacturing challenges and reduced energy density.
Innovation Solution
A battery design featuring a curved metal shell with side walls that extend from its surface, bound to a curved metal plate, securely sealing a curved electrode assembly, which allows for easier assembly and increased energy density by adapting to internal electronic equipment space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a curved battery is designed to meet ergonomic requirements and increase space utilization, then the energy density and adaptability are improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The battery shell is divided into a curved shell body and a separate curved plate, which are bound together through side walls. This segmentation allows the electrode assembly to be assembled first in a simpler configuration, then sealed within the curved shell structure, reducing the overall manufacturing complexity while maintaining the curved adaptive shape.
Solution Approach 2:
The electrode assembly is prepared and assembled into the curved shell before final sealing with the curved plate. This preliminary assembly approach allows the complex curved electrode structure to be formed independently, then integrated into the shell, simplifying the overall manufacturing process compared to attempting to assemble everything simultaneously.
2Reliability
If the electrode assembly is sealed within the curved shell, then the structural stability and reliability are improved, but the ease of manufacture deteriorates
Solution Approach 1:
The sealing structure is segmented into multiple side walls that bind the curved plate to the shell, rather than requiring a complex integrated sealing mechanism. This segmentation simplifies the manufacturing process while maintaining structural integrity and reliability of the sealed battery assembly.
Solution Approach 2:
The side walls are positioned at specific locations around the curved shell to provide localized binding and sealing functions. This local quality approach ensures structural stability at critical sealing points while keeping the overall manufacturing process simple and manageable.
3Reliability
If the curved shell has side walls extending from the curved surface, then the sealing capability is improved, but the device complexity increases
Solution Approach 1:
The side walls extending from the curved surface serve multiple functions: they provide structural support for the curved plate, create sealing surfaces, and facilitate binding between the shell and plate. This multi-functionality improves sealing capability while avoiding the need for additional separate components, thus not increasing overall device complexity.
Data Source
AI summary
A battery including a curved metal shell, a curved metal plate, and a curved electrode assembly. The curved metal shell has a curved surface and a plurality of side walls extending from the curved surface. The curved electrode assembly is disposed between the curved metal shell and the curved metal plate. The plurality of side walls are bound with the curved metal plate to seal the curved electrode assembly between the curved metal shell and the curved metal plate. By disposing a direction of an opening of the curved metal shell, the difficulty in the manufacturing process of the battery is greatly reduced, curved electrode assemblies in different structural forms are placed into the curved metal shell more conveniently and smoothly, and the energy density of the battery is also increased.