Integrally Formed Hard Case for Secondary Battery Assembly
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Solution Overview
Problem
The manufacturing of secondary batteries with hard cases is costly and inefficient due to the need for multiple materials and a complex molding process, which can damage the bare cell and make recycling difficult.
Innovation Solution
A secondary battery design featuring a hard case that is integrally formed, allowing for easy attachment and detachment, and a core pack connection via bending, reducing the number of parts and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard case is manufactured in advance and attached to a can using hot molten resin molding, then the battery case provides protection, but the bare cell breaks during the molding process due to heat and pressure, deteriorating yield and increasing cost
Solution Approach 1:
The hard case is manufactured in advance separately from the bare cell, allowing the case to be prepared and quality-checked before assembly. This preliminary manufacturing eliminates the need to expose the bare cell to high heat and pressure during case formation, preventing breakage while maintaining protective functionality.
Solution Approach 2:
The battery assembly is divided into separate components: the hard case and the bare cell are manufactured independently and then assembled together. This segmentation allows each component to be optimized and manufactured using appropriate processes without compromising the other, avoiding the breakage issue while maintaining protection.
2Strength
If multiple materials and processes are used to manufacture the hard case and molding case, then the case provides comprehensive protection, but the fabricating cost increases
Solution Approach 1:
The hard case and molding case are integrated into a single unified structure that provides both protection and molding functionality. This merging eliminates the need for separate manufacturing and assembly processes, reducing labor and material costs while maintaining comprehensive protection through the integrated design.
3Ease of manufacture
If the bare cell is attached to the hard case before molding, then the molding process can proceed, but the process time increases and recycling becomes difficult
Solution Approach 1:
The hard case is prepared in advance with the molding cavity formed beforehand, eliminating the need to attach the bare cell before molding. This preliminary preparation allows the molding process to proceed directly with the case alone, significantly reducing process time while maintaining feasibility.
Solution Approach 2:
The manufacturing process is segmented so that the hard case is molded separately from the bare cell assembly. This separation allows the case to be molded quickly without waiting for bare cell attachment, reducing overall process time while enabling easier recycling of the bare cell if needed.
Data Source
AI summary
A secondary battery having a hard case that is integrally formed to be able to reduce the number of parts and the fabrication process. The secondary battery includes at least one bare cell, a circuit part electrically coupled to the at least one bare cell and a case covering the circuit part coupled to the at least one bare cell, wherein the case includes a main case arranged on a first surface of the at least one bare cell and at least one sub case arranged on at least one different surface of the at least one bare cell that is adjacent to the first surface of the at least one bare cell, each of the at least one sub case being integral to the main case.