Prismatic Battery Case Manufacturing via Plate Bending and Welding
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Solution Overview
Problem
The deep drawing method for manufacturing prismatic battery cases is costly, time-consuming, and limited in material flexibility, leading to high production errors and restricted design options.
Innovation Solution
A method involving bending and welding a metal plate to create a prismatic body with open upper and bottom portions, followed by inserting an electrode assembly and sealing with corresponding upper and bottom portion members, reducing manufacturing complexity and costs while allowing for varied designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the deep drawing method is used to manufacture prismatic battery cases, then manufacturing efficiency is high, but manufacturing cost is extremely high and development time is greatly extended
Solution Approach 1:
The battery case is divided into multiple components: a bottom plate, side walls, and a top plate that can be separately manufactured and then assembled together. This segmentation eliminates the need for complex deep drawing molds while maintaining manufacturing efficiency, as each component can be produced using simpler, more cost-effective processes.
Solution Approach 2:
Multiple manufacturing steps are merged into a unified assembly process where pre-formed components (bottom plate, side walls, top plate) are joined together through welding or other joining methods. This merging approach simplifies the overall manufacturing process by replacing the complex multi-step deep drawing method with a more straightforward assembly-based approach.
2Productivity
If the deep drawing method is used to manufacture prismatic battery cases, then production speed is fast, but material selection is extremely limited
Solution Approach 1:
By segmenting the battery case into separate components (bottom plate, side walls, top plate), the invention enables the use of various materials for different parts. Each component can be manufactured from materials optimized for its specific function, such as using aluminum alloys for lightweight applications or steel for enhanced strength, without being constrained by the material limitations of the deep drawing process.
3Productivity
If the deep drawing method is used to manufacture prismatic battery cases, then continuous production is achieved, but manufacturing cost is extremely high
Solution Approach 1:
The segmentation of the battery case into separately manufacturable components allows each part to be produced using cost-effective processes. The bottom plate, side walls, and top plate can be manufactured using standard sheet metal forming, cutting, and bending operations, which are significantly less expensive than the specialized deep drawing molds required for continuous production of integrated cases.
Solution Approach 2:
Components such as the bottom plate, side walls, and top plate are prepared in advance through preliminary manufacturing steps (cutting, forming, reinforcing) before final assembly. This preliminary action approach allows for optimized, cost-effective production of individual components that can then be quickly assembled, reducing overall manufacturing cost while maintaining production efficiency.
4Productivity
If the deep drawing method is used to manufacture prismatic battery cases, then high production volume is achieved, but error rate increases due to edge cracks
Solution Approach 1:
By dividing the battery case into separate components (bottom plate, side walls, top plate), the invention eliminates the edge crack problem associated with deep drawing. Each component can be manufactured with controlled edges and proper reinforcement, and the assembly process allows for quality inspection and adjustment, significantly reducing the error rate while maintaining high production volume.
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 simplifies the manufacturing process, reduces production time, and lowers costs, enabling the production of prismatic battery cells with improved yield and reduced error rates.
Implementation Method 1
bending and then welding a metal plate having a predetermined thickness to manufacture a prismatic body
Implementation Method 2
contacting and then welding the bottom portion of the prismatic body and the bottom portion sealing member
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Disclosed is a method of manufacturing a battery cell, which is sealed inside a prismatic battery case, including an electrode assembly which includes a cathode, an anode and a separator interposed between the cathode and the anode. The method includes (a) bending and then welding a metal plate having a predetermined thickness to manufacture a prismatic body in which an upper portion and bottom portion are open; (b) manufacturing an upper and bottom portion sealing member corresponding to shape of each of the upper portion and the bottom portion of the prismatic body; (c) contacting and then welding the bottom portion of the prismatic body with the bottom portion sealing member; (d) inserting the electrode assembly into the battery case, the bottom portion of which is sealed, manufactured according to step (c); and (e) contacting and then welding the upper portion of the battery case manufactured according to step (d) with the upper portion sealing member.