Prismatic Cell Cover Assembly for Simplified Manufacturing

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Solution Overview

Problem

The manufacturing of large prismatic cells is complicated due to deep openings in the housing, increasing manufacturing time and costs, especially when cell capacity is modified, as it requires new housing and top cover specifications.

Innovation Solution

A cell design featuring a front cover with a cavity and a rear cover with a corresponding cavity, where the electrode group is connected to terminals before being covered, simplifying the manufacturing process and allowing only the rear cover's side wall height to be modified for different capacities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the housing is formed as a single piece with a deep opening to accommodate the electrode group, then the electrode group can be completely enclosed, but the manufacturing difficulty increases significantly

Engineering Contradiction:

Improveenclosure completenessVSAvoidhousing manufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The housing is divided into two separate parts: the top cover and the bottom cover. Each cover has a shallow opening that is easier to manufacture than a single deep opening. The electrode group is placed between these two covers, achieving complete enclosure while avoiding the manufacturing difficulties of deep extrusion or stamping.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If the top cover is fixed before connecting the electrode tabs, then the housing structure is stable, but the manufacturing time increases due to manual connection required

Engineering Contradiction:

Improvehousing structure stabilityVSAvoidmanufacturing time

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The electrode tabs are connected to the electrode group before the top cover is fixed. This preliminary connection allows the electrode assembly to be prepared in advance, and the top cover can then be attached without requiring complex manual connections during the final assembly, thus reducing manufacturing time while maintaining structural stability.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If new housing and top cover specifications are manufactured for increased cell capacity, then the electrode group can be accommodated, but the manufacturing costs increase

Engineering Contradiction:

Improvecell capacity adaptabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The top cover and bottom cover are designed as universal components that can accommodate different electrode group thicknesses. By adjusting only the spacer thickness or electrode group configuration while keeping the covers the same, the design achieves adaptability to different cell capacities without requiring new cover specifications, thus reducing manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10205140B2Cell and manufacture method thereof

Publication Date: 2019.02.12 DELTA ELECTRONICS INC(CN)

AI summary

A cell includes a front cover having a front cavity, a rear cover having a rear cavity, a first terminal, a second terminal, and an electrode group. The rear cover is connected to the front cover. The first terminal is disposed on the front cover and passes through the front cover to the front cavity. The second terminal is disposed on the front cover, and passes through the front cover to the front cavity. The electrode group is disposed in the front cavity and the rear cavity, and connected to the first terminal and the second terminal in the front cavity.