Segmented Prismatic Battery Cell Case for Rigidity and Sealing
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Solution Overview
Problem
Conventional pouch-shaped batteries face issues with low rigidity, susceptibility to damage from external impacts, and reduced capacity due to sealed surplus portions, while prismatic batteries have high manufacturing costs and limited shape options due to deep drawing processes.
Innovation Solution
A prismatic battery cell design featuring two or more case members coupled with stair-type steps to surround an electrode assembly, along with a cap plate, enhancing rigidity and safety, allowing for various designs without the limitations of deep drawing, and reducing manufacturing costs and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pouch-shaped battery case is used, then manufacturing cost is reduced and weight is decreased, but rigidity is insufficient and susceptibility to external impact damage increases
Solution Approach 1:
The battery case is divided into multiple separate case members (first case member, second case member, third case member) instead of using a single pouch-shaped case. These segmented members are coupled together to form the complete battery case, providing both structural strength and manufacturing flexibility.
Solution Approach 2:
The battery case combines multiple case members made of different materials or structures, coupled together with coupling members to create a composite structure that achieves both rigidity and cost-effectiveness, overcoming the limitations of single-material pouch cases.
2Manufacturing precision
If a deep drawing process is used for prismatic battery cases, then manufacturing precision is improved, but manufacturing cost increases and shape flexibility is limited
Solution Approach 1:
The case is segmented into multiple members that can be manufactured using simpler processes and then assembled together, avoiding the need for expensive deep drawing processes while maintaining manufacturing precision through the coupling structure.
Solution Approach 2:
Instead of forming a complete case using deep drawing and then modifying it, the invention inverts the approach by assembling multiple pre-formed case members into the final case structure, achieving precision through assembly rather than monolithic forming.
3Reliability
If sealed surplus portions are added to pouch-shaped batteries, then safety is improved, but battery capacity is reduced
Solution Approach 1:
The case is segmented into multiple members with coupling portions, allowing safety features to be integrated into the coupling structure itself rather than requiring separate sealed surplus portions that would reduce battery capacity.
Solution Approach 2:
The coupling members and coupling portions serve multiple functions: they provide structural connection between case members, ensure proper sealing, and contribute to overall safety, eliminating the need for dedicated sealed surplus portions that would consume battery capacity.
Data Source
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AI summary
Disclosed herein is a prismatic battery cell including an electrode assembly including a positive electrode, a negative electrode, and a separator disposed between the positive electrode and the negative electrode, the electrode assembly having a positive electrode terminal and a negative electrode terminal protruding from at least one side of the positive electrode and the negative electrode, two or more case members coupled to each other so as to have a shape corresponding to the external shape of the electrode assembly such that the case members surround the electrode assembly, the case members having a predetermined opening, through which one surface of the electrode assembly, at least, corresponding to protruding portions of the positive electrode terminal and the negative electrode terminal is exposed, and a cap plate coupled to the opening of the case members in a sealed state.