Roll-Groove-Free Battery Casing for Higher Cell Capacity
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Solution Overview
Problem
Existing battery designs with roll grooves face challenges such as increased height, risk of casing breakage, and reduced battery capacity due to the need for a roll grooving process and the space taken up by the roll groove and tab fold.
Innovation Solution
A battery design without a roll groove, utilizing a novel collector plate structure and a method of connecting it to the cap, which includes a cap, an outer washer, a casing, and a rolled core, where the rolled core is fixed and sealed within the casing without a roll groove, allowing for a reduction in the height of the cap and an increase in the rolled core height and electrolyte volume, thereby enhancing battery capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a roll groove structure is provided on the battery casing to fix the rolled core, then the rolled core stability is improved, but the battery height increases and the battery capacity is reduced
Solution Approach 1:
The invention removes the roll groove structure from the battery casing entirely. Instead of modifying the casing with a roll groove, the patent uses a cap assembly with a clamping structure that secures the rolled core through external clamping forces, thereby extracting the harmful element (roll groove) that consumes battery height while maintaining rolled core stability through an alternative mechanism.
Solution Approach 2:
The invention transitions from a vertical fixation approach (roll groove in the casing) to a horizontal clamping approach (cap assembly with clamping structure). By changing the dimension of the fixation mechanism from vertical to horizontal, the patent eliminates the need for vertical space consumption while maintaining the rolled core's positional stability.
2Stability of the object's composition
If a roll groove is formed using a hobbing cutter, then the rolled core is fixed in the casing, but the risk of casing breakage increases and production complexity increases
Solution Approach 1:
The invention removes the hobbing cutter roll grooving process entirely from the manufacturing sequence. The rolled core fixation function is extracted from the casing formation process and relocated to the cap assembly installation process, eliminating the harmful mechanical cutting action that risks casing breakage while maintaining effective rolled core fixation.
Solution Approach 2:
The invention performs the rolled core fixation action after the casing is already assembled and the rolled core is in place, rather than forming the fixation structure during casing formation. The cap assembly with the clamping structure is installed as a preliminary action to secure the rolled core, avoiding subsequent need for destructive roll grooving operations.
3Ease of manufacture
If the tab is folded to be accommodated between the cap and rolled core, then the cap connection is achieved, but the battery height is reduced and space is wasted
Solution Approach 1:
The invention removes the tab folding operation from the manufacturing process. Instead of folding the tab to connect the cap to the rolled core, the patent uses a direct clamping connection mechanism where the cap assembly's clamping structure secures the rolled core without requiring tab manipulation, thereby eliminating the height reduction caused by tab folding while maintaining ease of manufacture.
4Stability of the object's composition
If a roll groove structure is provided on the battery casing, then the rolled core is fixed, but the production cost increases due to the additional roll grooving process
Solution Approach 1:
The invention removes the roll grooving process step from the production sequence entirely. The rolled core fixation function is achieved through the cap assembly installation process, extracting the unnecessary manufacturing step that increases production time and cost while maintaining effective rolled core fixation.
Data Source
AI summary
A battery with no roll groove comprising a cap, an outer washer, a casing and a rolled core, wherein the rolled core is accommodated in the casing, and the cap is electrically connected to the rolled core; a top portion of the casing is bent inward and tightly presses the outer washer against the cap, thereby fixing the rolled core in the casing; the casing has no roll groove structure. The outer washer comprises an outer washer top portion, the outer washer top portion being an annular structure, and the cap being exposed through a central round opening; and an outer washer bottom portion, disposed between the cap and the casing.