Metal-Frame Lithium-Ion Battery Packaging for Leak-Tight Reliability
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Solution Overview
Problem
Lithium ion batteries face issues with pouch-type batteries having undesirable long-term reliability due to liquid leakage and aluminum-shell batteries having complex packaging leading to low gravimetric energy density and high costs.
Innovation Solution
A lithium ion battery design incorporating a metal frame, metal plates, and an explosion-proof valve, with a simple manufacturing process that integrates the advantages of pouch-type batteries' simplicity and aluminum-shell batteries' reliability, using thin metal components for high volumetric energy density and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pouch-type battery packaging is used, then structure simplicity and gravimetric energy density are improved, but long-term reliability deteriorates due to liquid leakage
Solution Approach 1:
The patent employs a composite packaging structure combining aluminum shell with plastic sealing layers and rubber gaskets. This multi-material approach integrates the mechanical strength and corrosion resistance of aluminum with the sealing advantages of plastic and rubber, achieving both structural simplicity and long-term reliability against liquid leakage
Solution Approach 2:
The patent utilizes thin plastic sealing films and rubber gaskets within the aluminum shell structure. These flexible sealing elements conform to the cell contours and provide effective liquid-tight sealing while maintaining the overall simplicity and light weight of the pouch-type packaging
2Reliability
If aluminum-shell battery packaging is used, then long-term reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a hybrid packaging system that retains the aluminum shell for structural integrity and corrosion resistance but combines it with simpler plastic and rubber sealing components. This composite approach achieves aluminum-shell level reliability while reducing overall structural complexity compared to traditional aluminum-shell designs
Solution Approach 2:
The packaging structure is divided into distinct functional segments: the aluminum shell provides mechanical protection and corrosion resistance, while separate plastic sealing layers and rubber gaskets handle liquid containment. This segmentation allows each component to be optimized for its specific function, simplifying manufacturing and assembly
3Reliability
If aluminum-shell battery packaging is used, then reliability is improved, but gravimetric energy density deteriorates
Solution Approach 1:
The patent employs thin plastic sealing films and rubber gaskets that are significantly lighter than traditional aluminum-shell components. These thin-film sealing solutions provide adequate liquid containment while minimizing added weight, thereby improving gravimetric energy density compared to conventional aluminum-shell batteries
Solution Approach 2:
By combining lightweight plastic and rubber materials with minimal aluminum components, the patent creates a hybrid structure that achieves the corrosion resistance and reliability of aluminum-shell batteries while dramatically reducing overall weight, thus improving gravimetric energy density
Data Source
AI summary
Provided are an electric vehicle, and a lithium ion battery and a manufacturing method therefor. The lithium ion battery includes a first metal plate, a second metal plate, a metal frame, a battery cell, poles, and an explosion-proof valve; the first metal plate, the metal frame, and the second metal plate are sequentially connected to form a mounting chamber; the battery cell is accommodated in the mounting chamber; the poles are provided on the metal frame in an insulating manner and are electrically connected to the battery cell; the explosion-proof valve is provided on the metal frame; and the metal frame is provided with a liquid injection hole.