Steel Battery Casing with Melting Insulator for Explosion Prevention
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Solution Overview
Problem
Rechargeable batteries using the pouch method face limitations in shaping due to aluminum deformation and high manufacturing costs, and there is a risk of explosion from overheating.
Innovation Solution
A rechargeable battery design using metallic plates made of steel or stainless steel, laser-welded to form a hexahedron structure with a cap assembly including an insulator that melts at elevated temperatures to prevent explosions, allowing for thicker batteries with reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If aluminum pouch method is used to close and seal the outside of generation element, then the battery can be sealed effectively, but the manufacturing cost increases and the battery thickness is limited to less than 6-7 mm
Solution Approach 1:
The patent changes the material parameter from aluminum to steel or stainless steel, which allows the battery to achieve greater thickness (exceeding 6-7 mm) while maintaining structural integrity. This material substitution resolves the limitation on battery thickness imposed by the aluminum pouch method.
Solution Approach 2:
The patent replaces the mechanical sealing method (pouch method with aluminum and polypropylene) with a laser welding method using steel plates. This substitution eliminates the deformation issues and thickness limitations of the pouch method while reducing manufacturing costs through more efficient sealing.
2Ease of manufacture
If aluminum material is used for battery casing, then the battery can be formed effectively, but the manufacturing cost increases due to high aluminum price
Solution Approach 1:
The patent substitutes expensive aluminum material with cheaper steel or stainless steel materials for the battery casing. This material replacement directly reduces manufacturing costs while maintaining sufficient structural strength for battery containment.
Solution Approach 2:
The patent uses steel or stainless steel materials that combine strength, cost-effectiveness, and thermal stability properties. These composite material choices provide both mechanical strength and resistance to thermal deformation, resolving the contradiction between cost and strength.
3Reliability
If aluminum pouch method is used for battery sealing, then the battery can be assembled, but there is a danger of explosion when abnormal overheating occurs
Solution Approach 1:
The patent converts the harmful effect of overheating into a beneficial safety mechanism. The steel plate structure with laser-welded seams is designed to deform or open at specific temperature thresholds, converting the harmful overheating condition into a controlled venting mechanism that prevents catastrophic explosion.
Solution Approach 2:
The patent incorporates inherent safety features in the steel plate design that provide beforehand cushioning against overheating. The material properties and welding structure are designed to withstand normal operating temperatures while automatically responding to abnormal heat conditions, providing prior protection against explosion risks.
4Shape
If pouch method with polypropylene coating is used, then the battery can be sealed, but the external shape molding is limited due to deformation of aluminum and polypropylene
Solution Approach 1:
The patent replaces the mechanical pouch sealing system with a laser welding system using steel plates. This substitution eliminates the deformation issues of aluminum and polypropylene, allowing for precise external shape molding while maintaining effective sealing through the rigid steel structure and controlled welding joints.
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
The solution enables the production of thicker rechargeable batteries with reduced manufacturing costs and prevents explosions from overheating by automatically venting pressure through the melting insulator, enhancing battery stability.
Implementation Method 1
a cap assembly including an insulator and at least one electrode lead coupled to the at least one connection member, the cap assembly closing the opening
Implementation Method 2
having metal portions thereof closed or coupled by laser welding
Data Source
AI summary
A rechargeable battery configured to prevent or substantially prevent explosion resulting from overheating. In one embodiment, a rechargeable battery includes: a first metallic plate; a second metallic plate coupled to the first metallic plate to together include five sides of a hexahedron and define a cavity and an opening to the cavity being a sixth side of the hexahedron, at least one of the first metallic plate or the second metallic plate including a base and walls extending from at least two opposing peripheral sides of the base; a generation member in the cavity and including at least one connection member at a side of the generation member proximate the opening; and a cap assembly including an insulator and at least one electrode lead coupled to the at least one connection member, the cap assembly closing the opening.