Pouch Battery Case Folding Guides to Prevent Bat Ear Sealing

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Solution Overview

Problem

Existing secondary battery manufacturing methods result in size errors and reduced energy density to volume ratios due to the formation of bat ears during the folding and sealing process of pouch type battery cases.

Innovation Solution

An apparatus and method utilizing a first guide with a recessed concave space to push the folding part of the battery case outside, and a second guide to hold the sealing part, allowing for precise folding and sealing without forming bat ears, thereby reducing size errors and increasing energy density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the battery case is folded to seal the sealing part, then the number of edges to be sealed is reduced, but a bat ear protrudes causing size error and increased volume

Engineering Contradiction:

Improveprocess rateVSAvoidsize accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The guide structure performs preliminary action by pushing the folding part outward before the sealing process occurs. This prevents the bat ear from forming during sealing, thereby maintaining size accuracy while still reducing the number of edges to be sealed for improved productivity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The guide acts as an intermediary structure between the folding part and the sealing process. It mediates the folding action to prevent unwanted protrusion, enabling both efficient sealing (3 edges) and precise size control without direct intervention during sealing

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the battery case is folded to seal the sealing part, then the number of edges to be sealed is reduced, but the volume of the secondary battery increases

Engineering Contradiction:

Improveprocess rateVSAvoidbattery volume

Core Design Contradiction:

ProductivityVSVolume of stationary object

Solution Approach 1:

The guide structure performs preliminary action by pushing the folding part outward before sealing, preventing bat ear formation. This eliminates unnecessary volume increase while maintaining the productivity benefit of sealing only three edges

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The guide converts the potentially harmful folding action (which creates bat ears and increases volume) into a beneficial process. By controlling the folding direction outward, the same folding mechanism that could cause harm now prevents volume increase while still enabling efficient sealing

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If the folding part is allowed to protrude during sealing, then the sealing process is simpler, but assembly of secondary batteries becomes difficult

Engineering Contradiction:

Improvesealing easeVSAvoidassembly ease

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The guide performs preliminary action by positioning the folding part outward before sealing, preventing bat ear formation. This maintains simple sealing process while eliminating the protrusion that complicates assembly, thereby improving both sealing ease and assembly ease

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12308392B2Apparatus and method for manufacturing secondary battery

Publication Date: 2025.05.20 LG ENERGY SOLUTION LTD

AI summary

An apparatus for manufacturing a secondary battery includes a first guide in which one side of one end is recessed to define a concave space, wherein, when a battery case of the secondary battery is folded, the one end is configured to be inserted into the battery case to push a folding part of the battery case to an outside; and a second guide configured to hold a sealing part of the battery case so as to fix the battery case.