Rounded Corner Rechargeable Battery Can Impact Resistance
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Solution Overview
Problem
Rechargeable batteries face reliability issues due to mechanical damage from impacts, leading to potential electrical short circuits or electrolyte leakage, as existing designs lack sufficient resistance to external shocks and drops.
Innovation Solution
A rechargeable battery design featuring a hexahedral can with rounded corner units, where the outer radius of curvature is greater than the inner radius, and a thicker bottom surface compared to the side surfaces, enhancing the distribution of forces and preventing can rupture during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the can has sharp corner units, then the manufacturing process is simpler, but the resistance to impacts and drops is insufficient
Solution Approach 1:
The corner units of the can are designed with rounded shapes instead of sharp edges. The outer surface of each corner unit has a curved profile with a specific radius of curvature, which distributes impact forces more effectively and prevents stress concentration that would occur at sharp corners during drops or external impacts.
2Reliability
If the can has uniform thickness throughout, then the manufacturing process is simpler, but the structural integrity during impacts is reduced
Solution Approach 1:
The can exhibits non-uniform thickness distribution: the bottom surface has a greater thickness than the side surfaces. This local variation in thickness provides enhanced structural support at the bottom where impact forces are most likely to occur, while maintaining simpler geometry in the side walls.
3Reliability
If the outer radius of curvature equals the inner radius of curvature at corner units, then the manufacturing precision requirement is lower, but the force distribution during impacts is insufficient
Solution Approach 1:
The corner units are designed with a specific curvature relationship where the outer radius of curvature is greater than the inner radius of curvature. This creates a gradually transitioning rounded profile that effectively distributes tensile forces across the corner unit during impacts, preventing stress concentration while maintaining manufacturability.
Data Source
AI summary
A rechargeable battery is disclosed. In one aspect, the battery includes an electrode assembly that comprises a first electrode plate, a second electrode plate, and a separator interposed between the first and second electrode plates. The battery also includes a can having an opening and accommodating the electrode assembly therein, wherein the can comprises a plurality of corner units, wherein at least one of the corner units is rounded, and wherein the outer radius of curvature of the at least one corner unit is greater than the inner radius of curvature thereof. The battery further includes a cap plate substantially sealing the opening of the can.