Folded Battery Housing Structure for Higher Yield and Cell Density
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Solution Overview
Problem
The existing battery housing designs, particularly for lithium-ion batteries, face issues with low processing yield due to breakage of R round corners and fold deformation during stretching, and limited effective space utilization, which restricts energy density improvement.
Innovation Solution
A battery housing design featuring a plate body with multiple folding portions and side plates that fold to create an accommodating space, using cover plates to close open ends, and incorporating a lining plate and sealing cover for improved airtightness and space efficiency, made from materials like nickel, nickel alloy, or alloy steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If alloy housing is formed by stamping and stretching, then pressure resistance and battery package reliability are improved, but R round corners break and generate fold deformation, resulting in low processing yield
Solution Approach 1:
The housing is divided into a body portion and a separate cap portion that can be assembled together. The body portion is formed by stamping and stretching to provide pressure resistance, while the cap portion is separately formed and then assembled to the body, avoiding the corner breakage issue in the stretching process while maintaining the reliability benefits.
Solution Approach 2:
The body portion and cap portion are combined through welding or other connection methods to form the complete housing. This merging allows each part to be optimized independently - the body for pressure resistance and the cap for ease of formation - while achieving the overall functional requirements.
2Reliability
If flanges for welding and sealing are added to peripheries of housing, then sealing and connection are enabled, but general space of battery is occupied, limiting effective space utilization rate and energy density
Solution Approach 1:
The sealing function is extracted from the main housing body and concentrated into the cap portion. The cap includes sealing structures that provide the necessary sealing function without requiring large flanges on the housing body, thereby reducing space occupation and improving effective space utilization.
Solution Approach 2:
The cap portion uses thin-walled structures with integrated sealing features that provide adequate sealing performance without the bulk of traditional flange designs. This allows for more efficient space utilization while maintaining sealing reliability.
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 design enhances processing yield, reduces space occupation, and improves energy density by avoiding corner breakage and flange-related space limitations, while simplifying production procedures and enhancing airtightness.
Implementation Method 1
The plate body is folded along the folding portions such that the side plates are connected to create an accommodating space
Implementation Method 2
two cover plates disposed along the first direction on two sides of the side plates. When the plate body is folded, two open ends of the middle housing are closed by the two cover plates
Implementation Method 3
The two cover plates and the middle housing are welded to close the two open ends of the middle housing
Data Source
AI summary
A battery housing includes a plate body. The plate body has multiple folding portions and multiple side plates connected by the folding portions. The plate body is folded along the folding portions such that the side plates are connected to create an accommodating space for accommodating an electrochemical unit inside the middle housing.