Segmented Prismatic Battery Can Joining for Longer Cell Length
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Solution Overview
Problem
Conventional deep drawing methods for manufacturing metal cans for P-type prismatic battery cells are limited by issues such as wrinkling, fracturing, uneven wall thickness, and limited length, which restricts the size of the battery cell and results in reduced energy density and increased weight in electric vehicles.
Innovation Solution
A method involving the use of different manufacturing processes, including high precision cutting and die bending, to create flanged portions of the battery can, followed by laser welding, which allows for increased length and uniform wall thickness, and the optional application of insulation coatings and safety vents for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If deep drawing method is used to manufacture metal cans, then manufacturing process is simple, but the can length is limited to approximately 300-350 millimeters
Solution Approach 1:
The battery can is divided into multiple segments (first can body portion and second can body portion) that are manufactured separately using deep drawing and then joined together. This segmentation allows each portion to be made within the feasible length range of the deep drawing process while achieving an overall can length that exceeds 350 millimeters, thereby resolving the contradiction between simple manufacturing and long can length.
2Manufacturing precision
If deep drawing method is used, then manufacturing is straightforward, but wall thickness becomes uneven
Solution Approach 1:
By dividing the can into multiple segments manufactured separately and then joining them, the patent ensures that each segment maintains uniform wall thickness characteristics typical of deep drawing processes. The segmentation allows for better control of wall thickness in each individual portion, avoiding the cumulative thickness variations that would occur in a single long-drawn piece.
3Reliability
If deep drawing method is used, then process is conventional, but wrinkling and fracturing occur
Solution Approach 1:
Segmenting the can into multiple shorter portions reduces the stress and deformation requirements for each individual deep drawing operation, thereby minimizing the risk of wrinkling and fracturing. Each segment can be drawn within optimal dimensional ranges, improving structural integrity while avoiding the defects associated with attempting to draw a single extremely long can.
4Quantity of substance
If can length is limited by deep drawing, then manufacturing is easier, but energy density decreases
Solution Approach 1:
The segmentation approach enables the production of longer cans that can accommodate larger electrode stacks, directly increasing the quantity of active materials and thus the energy density. The added complexity of joining segments is offset by the significant gain in usable battery capacity and energy storage per unit volume.
5Weight of moving object
If can length is limited by deep drawing, then manufacturing is simpler, but battery pack weight increases
Solution Approach 1:
By enabling longer can lengths through segmentation, the patent increases the energy capacity of each battery cell. This means fewer cells are needed to achieve the same total battery pack capacity, ultimately reducing the overall weight of the battery pack despite the added joining complexity in manufacturing.
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 approach enables the production of longer battery cans with improved energy density and thermal protection, reducing battery pack weight and enhancing electric vehicle mileage performance.
Implementation Method 1
joining the first portion having the first contour and the second portion having the second contour, using a third manufacturing process... the third manufacturing process may be, but is not limited to, a laser welding process
Data Source
AI summary
A method for making a battery can, for example, but not limited to, for a p-type prismatic cell may include: manufacturing at least one first battery can portion and at least one second battery can portion, using a first manufacturing process; joining the at least one first battery can portion and the at least one second battery can portion, using a second manufacturing process, different from the first manufacturing process; and inspecting the battery can to verify the joining between the at least one first portion and the at least one second portion. A method for making a battery can may include: providing at least one safety vent in a battery can and/or applying an insulation coating to one or more of an internal surface, an external surface and at least one seam of the battery can.