Voltage-Reduced Lithium Battery Housing for Strong Sealed Assembly
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Solution Overview
Problem
Existing low-voltage lithium batteries have high costs and are prone to damage due to low connection strength between components.
Innovation Solution
A voltage-reduced lithium battery design featuring a circuit assembly and plastic frame in a first metal housing, with a wound battery core assembly in a second metal housing, connected via an insulating seal and circumferential welding, and covered with an insulating sheath to enhance sealing and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasonic welding is used to connect covers to steel housing, then assembly is simplified, but connection strength is reduced and damage tendency increases
Solution Approach 1:
The patent merges the cover and steel housing into a single integrated steel housing structure. The upper cover is formed as an integral part of the steel housing through stamping and folding operations, eliminating the need for separate welding operations. This integration maintains structural strength while simplifying the manufacturing process by removing the weak welded joints.
Solution Approach 2:
The patent extracts the weak ultrasonic welding step from the manufacturing process and replaces it with a forming operation. The connection between cover and housing is achieved through mechanical forming (folding and crimping) rather than thermal welding, thereby eliminating the source of weak connections and damage tendency.
2Strength
If multiple steel housings are used to enclose battery core, then structural strength is improved, but material cost increases
Solution Approach 1:
The patent combines multiple protective housing functions into a single steel housing structure. The housing simultaneously provides mechanical strength, electrolyte containment, and structural support that would traditionally require multiple separate components. This consolidation reduces material usage and cost while maintaining or improving overall structural integrity through optimized design.
Solution Approach 2:
The single steel housing performs multiple functions: it serves as the outer protective shell, the electrolyte containment vessel, the structural frame, and the mounting structure for internal components. This multi-functionality eliminates the need for separate housings for each purpose, reducing material cost while maintaining comprehensive structural strength.
3Strength
If circumferential welding is used to connect metal housings, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the complex circumferential welding operation and replaces it with simpler mechanical connection methods. The metal housings are connected through interlocking features, snap-fits, or mechanical fasteners that achieve sufficient connection strength without requiring welding equipment, skill, or post-weld treatment, thereby reducing manufacturing complexity.
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
The design achieves a strong connection between components, prevents electrolyte leakage, reduces material costs by minimizing the number of steel housings, and ensures electrical safety by preventing short circuits.
Implementation Method 1
the first metal housing and the second metal housing are in vertical butt connection and fixed by circumferential welding
Implementation Method 2
the insulating seal is arranged between the first metal housing and the second metal housing and configured to seal the second metal housing
Implementation Method 3
the plastic frame is configured to fix the circuit assembly
Implementation Method 4
the insulating sheath covers the first metal housing and the second metal housing
Data Source
AI summary
The present application relates to a voltage-reduced lithium battery and a manufacturing method thereof. The voltage-reduced lithium battery includes a circuit assembly, a plastic frame, a wound battery core assembly, a first metal housing, a second metal housing, an insulating seal and an insulating sheath, wherein the circuit assembly and the plastic frame are arranged in the first metal housing, the wound battery core assembly is arranged in the second metal housing, the first metal housing and the second metal housing are in vertical butt connection and fixed by circumferential welding, the insulating seal is configured to seal the second metal housing, and the insulating sheath covers the first metal housing and the second metal housing.