Pouch Battery Case Curvature Design for Deep Draw Moldability
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Solution Overview
Problem
Pouch-type battery cases face limitations in achieving high energy density, elegant appearance, and marketability due to constraints in molding small curvature radii and deep depths, which also lead to issues like cracks and pin-holes.
Innovation Solution
The pouch-type battery case design features a cup part with specific curvature radii and thicknesses for its edges and surfaces, optimized to reduce empty space and enhance moldability, ensuring a deeper depth without increasing the risk of cracks or pin-holes, while maintaining a compact and aesthetically pleasing form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the barrier layer is made with large crystal grain size aluminum alloy and thin thickness, then the manufacturing cost is reduced, but the moldability is deteriorated and cracks and pin-holes are formed
Solution Approach 1:
The patent changes the crystal grain size parameter of the aluminum alloy from large to fine (10-15 μm), which fundamentally alters the material's moldability and mechanical properties, allowing thin layers to be formed without defects while maintaining cost efficiency
Solution Approach 2:
The patent creates a composite pouch film structure with multiple layers including the fine-grain aluminum alloy barrier layer, combining materials with different properties to achieve both thin thickness and high moldability, preventing cracks and pin-holes during deep cup part molding
2Quantity of substance
If the cup part is molded with deep depth, then the energy density is increased, but the curvature radius of edges becomes large and moldability is limited
Solution Approach 1:
The patent changes the material parameters of the pouch film (fine crystal grain size, specific thickness range) to enable the formation of deep cup parts with small edge curvature radii, resolving the limitation that normally prevents deep molding
3Volume of stationary object
If the pouch film is molded deeply, then the accommodation space is increased, but the film thickness is reduced and pin-holes are formed
Solution Approach 1:
The patent optimizes the film thickness parameter within a specific range (15-25 μm for the barrier layer) and changes the crystal grain size to fine, enabling deep molding that creates large accommodation space while the fine-grain structure prevents pin-hole formation during the molding process
Solution Approach 2:
The multi-layer composite structure provides both the necessary thickness for deep molding and the fine-grain barrier layer that prevents pin-hole formation, maintaining film integrity while maximizing accommodation space
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 increases energy density, improves the outer appearance, and enhances marketability by minimizing defects like cracks and pin-holes, allowing for more efficient manufacturing and better performance.
Implementation Method 1
the aluminum alloy thin film has a crystal grain size of 10 μm to 15 μm, thereby moldability is improved
Data Source
AI summary
A pouch-type battery case is disclosed herein. The pouch-type battery case can include a cup part having a recessed shape, and a side disposed around at least a portion of the cup part. The cup part can include a base surface, a plurality of circumferential surfaces, a plurality of die edges connecting the plurality of circumferential surfaces and the side and formed to be rounded, and a plurality of thickness edges connecting the plurality of circumferential surfaces to each other and formed to be rounded.A curvature radius of each of the die edges is Rd, a curvature radius of each of the thickness edges is Rt. The Rd and Rt can satisfy a condition defined by Rd≤Rt<3*Rd is satisfied.