Dual-Cap Rechargeable Battery Structure for Stable High-Capacity Cells
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Solution Overview
Problem
Prismatic lithium-ion batteries for electric vehicles face challenges with increased width affecting dimensional stability, longer welding lengths, and complex process control due to the number of electrode assemblies, which increase manufacturing costs and complexity.
Innovation Solution
A rechargeable battery design with reduced cap plate welding length, oriented vent direction, and increased electrode assembly size, featuring a first and second cap plate coupled to the case, cover members with exposed terminals, and electrode leads passing through these plates for efficient manufacturing and venting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the width of a prismatic cell is increased to accommodate more electrode assemblies, then the energy capacity is improved, but the dimensional stability of the case deteriorates and the welding length of the cap plate becomes longer
Solution Approach 1:
The patent transitions from a traditional wide prismatic configuration to a taller cylindrical configuration, changing the primary dimension for capacity expansion from width to height. This allows increased electrode assembly capacity while maintaining case dimensional stability and reducing cap plate welding length.
2Quantity of substance
If the width of a prismatic cell is increased to accommodate more electrode assemblies, then the energy capacity is improved, but the welding length of the cap plate becomes longer making process control difficult
Solution Approach 1:
By changing from a wide prismatic design to a tall cylindrical design, the patent reduces the cap plate welding length, thereby improving manufacturability and process control while still achieving high energy capacity through vertical stacking of electrode assemblies.
3Quantity of substance
If multiple electrode assemblies are used to increase capacity, then the energy capacity is improved, but the number of assemblies increases manufacturing cost and complexity
Solution Approach 1:
The patent combines multiple electrode assemblies into a single cylindrical case with a unified structure, integrating them vertically rather than horizontally. This merging approach reduces the number of separate components and simplifies manufacturing processes while maintaining high capacity.
Data Source
AI summary
A rechargeable battery includes an electrode assembly including a first electrode plate, a second electrode plate, and a separator, a case accommodating the electrode assembly and having both ends open, a first cap plate coupled to one end of the case, a second cap plate coupled to the other end of the case, a first cover member disposed to cover the first cap plate and including a first electrode terminal exposed upwardly, and a second cover member disposed to cover the second cap plate and including a second electrode terminal exposed upwardly. A first electrode lead of the electrode assembly passes through the first cap plate to be electrically connected to the first electrode terminal of the first cover member, and a second electrode lead of the electrode assembly passes through the second cap plate to be electrically connected to the second electrode terminal of the second cover member.