Stepped Metal Can Battery Enclosure for Higher Energy Density
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Solution Overview
Problem
Conventional can battery cells are limited in size, shape, and configuration, making them unsuitable for powering small, powerful electronic devices with complex geometries and space constraints, which require higher energy density and non-standard enclosures.
Innovation Solution
Development of can batteries with stepped or non-standard enclosures made of rigid materials like steel, aluminum, or copper, featuring a metal enclosure with a protrusion on the front face to accommodate an anode or cathode tab and a circuit module, enhancing energy storage capacity by utilizing the void created by the protrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional can battery cells are used, then manufacturing simplicity and cost-effectiveness are maintained, but energy storage capacity and adaptability to non-standard device geometries are limited
Solution Approach 1:
The patent introduces a stepped enclosure design that extends in the thickness dimension, creating multiple levels or tiers within the battery structure. This dimensional approach allows the battery to utilize vertical space more effectively, increasing energy storage capacity without proportionally increasing the battery's footprint area. The stepped configuration enables the battery to fit into complex device geometries while maintaining high energy density.
Solution Approach 2:
The patent employs a nested structure where the battery cell is housed within a stepped enclosure that contains multiple compartments or levels. The internal components are arranged in a nested fashion, with the battery cell core positioned within the enclosure's stepped chambers. This nesting approach maximizes space utilization and allows for efficient packaging of energy storage components.
2Quantity of substance
If conventional can battery sizes are used, then standard manufacturing processes are maintained, but ability to power small powerful devices with high energy density requirements is insufficient
Solution Approach 1:
The patent applies local quality by creating regions of different densities and functions within the battery structure. The stepped enclosure divides the battery into zones with varying energy density characteristics, allowing high-energy-density regions to be positioned where space is most critical. This localized optimization enables the battery to meet high energy density requirements while adapting to diverse device size and shape constraints.
Solution Approach 2:
The patent utilizes parameter changes by varying the enclosure thickness, step heights, and compartment volumes to optimize energy density. By adjusting these geometric parameters, the battery can be customized for different device applications, achieving high energy density in compact form factors while maintaining adaptability to various size and shape requirements.
3Quantity of substance
If battery enclosure thickness is increased to store more energy, then energy storage capacity improves, but device size and weight increase
Solution Approach 1:
The stepped enclosure design transitions the battery's energy storage approach from purely horizontal expansion to vertical utilization. By creating multiple tiers in the thickness dimension, the battery achieves increased energy storage capacity within a compact volume. This dimensional strategy allows energy to be stored in vertical layers rather than requiring proportional increases in overall battery footprint.
Solution Approach 2:
The patent employs asymmetric stepped configurations where different portions of the battery enclosure have varying thicknesses and volumes. This asymmetry allows strategic placement of high-energy-density components in regions where volume is most efficiently utilized, maximizing energy storage capacity without uniformly increasing battery volume. The asymmetric design optimizes the distribution of energy storage materials across different spatial zones.
Data Source
AI summary
Can battery cells are described. The can battery cell includes a battery cell core that is housed in a rigid enclosure. The enclosure can be made of metal or other rigid material. A front face of the enclosure includes an anode tab and a cathode tab extending from the front face. A circuit module is electrically coupled to the anode tab and the cathode tab, and overlies at least a portion of the front face of the enclosure. One of the anode tab or the cathode tab is electrically coupled to the battery enclosure. The other of the anode tab or the cathode tab is electrically insulated from the enclosure. The front face includes a protrusion portion that forms a step-like structure in the front face of the enclosure.