Segmented Battery Cell Case for Thin-Wall Precision Forming
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Solution Overview
Problem
The molding difficulty of battery cell cases affects production costs and dimensional precision, particularly when thinner cases are required for improved energy density.
Innovation Solution
The battery cell case is formed by splicing at least two independently formed side plates, which are welded together to enclose a hollow tubular structure, with specific thickness and shape dimensions to enhance precision and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a case is integrally formed by stamping, then the manufacturing process is simple, but the thickness consistency and dimensional precision are poor
Solution Approach 1:
The case is divided into multiple side plates (at least two) that are formed independently and then spliced together. Each side plate can be manufactured separately with better thickness consistency, and the splicing allows for improved dimensional precision at corners and edges compared to integral stamping.
2Quantity of substance
If the case thickness is reduced to improve energy density, then the energy density increases, but the molding difficulty increases and strength decreases
Solution Approach 1:
By dividing the case into multiple thin side plates that are spliced together, each plate can be made with reduced thickness to improve energy density while maintaining manufacturability. The segmentation allows each component to be optimized independently.
Solution Approach 2:
Multiple thin side plates are combined through splicing to form the complete case structure. This merging of multiple thin components achieves the desired thin-walled case for improved energy density while distributing the manufacturing complexity across multiple simpler components.
3Quantity of substance
If the case thickness is reduced, then the energy density improves, but the strength and structural integrity deteriorate
Solution Approach 1:
Multiple thin side plates are merged through splicing to create the complete case structure. This combination distributes structural loads across multiple components and connection points, maintaining overall strength despite reduced individual plate thickness.
Solution Approach 2:
The side plates are formed independently with predetermined shapes and thicknesses before assembly. This preliminary formation allows for optimized thickness distribution and pre-stressed connections that enhance structural integrity while maintaining thin overall dimensions for high energy density.
4Manufacturing precision
If at least two side plates are used instead of an integral case, then the dimensional precision and thickness consistency improve, but the manufacturing process complexity increases
Solution Approach 1:
The case is segmented into multiple side plates that can be manufactured independently with consistent thickness control. This segmentation enables better precision in each component while the modular nature simplifies quality control and assembly compared to complex integral stamping.
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 method simplifies the manufacturing process, improves dimensional precision, reduces costs, and enhances energy density by ensuring consistent thickness and structural integrity.
Implementation Method 1
two adjacent side plates are welded in the circumferential direction of the case
Data Source
AI summary
The present application provides a battery cell case and a manufacturing method therefor, a battery cell, a battery, and an electric apparatus. The case comprises at least two side plates, wherein each side plate is independently formed, and the at least two side plates are sequentially arranged and connected in the circumferential direction of the case so as to enclose a hollow tubular structure.