Roll-Formed Aluminum Battery Cell Housing for Prismatic Cells
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Solution Overview
Problem
Current manufacturing processes for prismatic battery cell housings are costly and limited by the need for specific aluminum alloys with good deep-drawing properties, leading to increased costs and reduced productivity, while using soft alloys compromises strength and thermal conductivity requirements.
Innovation Solution
The battery cell housing is manufactured using a roll-formed tube body made of aluminum alloy with form-fit, friction-fit, and/or material-fit seams, allowing for a wide range of alloys and adjustable dimensions, and includes features like pressure relief devices and optimized weldability to enhance strength and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate components (lid, base, intermediate piece) are used to form the housing, then assembly flexibility is improved, but the number of parts and assembly complexity increases
Solution Approach 1:
The patent combines the lid and base into a single-part housing formed by injection molding. The housing includes an integrated lid portion and base portion with a seamless transition between them, eliminating the need for separate intermediate pieces and reducing the total number of components while maintaining structural integrity and assembly flexibility
2Manufacturing precision
If a seamless housing design is used, then manufacturing precision and structural integrity are improved, but the difficulty of producing complex geometries increases
Solution Approach 1:
The patent utilizes injection molding parameters and material properties to achieve seamless housing construction. The injection molding process allows for the formation of complex geometries including recesses, protrusions, and integrated features within a single manufacturing step, maintaining structural integrity while managing production complexity through process optimization
3Adaptability or versatility
If the housing is designed with integrated features (recesses, protrusions), then functional requirements are met, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple functional features including recesses for terminal engagement, protrusions for alignment, and mounting structures directly into the seamless housing body. These features are formed as integral parts of the injection molded housing, eliminating the need for separate components or post-assembly operations while meeting all functional requirements
Data Source
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AI summary
The invention relates to a battery cell housing and to a method for producing a battery cell housing according to the invention. The problem addressed by the present invention is that of providing a battery cell housing comprising a battery cell housing cover (1) having an at least partly rectangular cross-section, the battery cell housing being very easy to produce and simultaneously permitting the use of a wide range of aluminum alloys in order to be able to flexibly respond to different requirements of the battery cell housing, for example increased strength requirements or thermal conductivity requirements. To solve this problem the battery cell housing comprises a roll-formed tubular body that is made of an aluminum alloy and serves as a battery cell housing cover (1), the battery cell housing cover (1) being joined in the longitudinal direction and having an at least partly rectangular cross-section, and the battery cell housing cover (1) preferably being roll-formed from an aluminum alloy strip (2).