Novel battery cell based on prismatic structure

Abstract

The invention relates to a battery cell (100) based on a prismatic structure. The body is a prismatic body that provides a maximum flat surface as a cell terminal when the prismatic body redirects current. The main body comprises an anode layer (1), a diaphragm layer (2), a cathode layer (3), an adhesion layer (4), an upper current collector layer (5) and a lower current collector layer (6). The anode layer (1), the diaphragm layer (2), the cathode layer (3), the upper current collector layer (5), the adhesion layer (4), and the lower current collector layer (6) are fixed to each other by at least one of a mechanical contact process and a deposition process.

Description

Technical Field

[0001] This invention relates to the field of battery cells. More specifically, this invention relates to a battery cell based on a novel prismatic design, which allows for high fill rates for battery packs, better thermal management, lower production costs, and reduced cost complexity. Background Technology

[0002] Battery cells come in various configurations, such as pouch, prismatic, and cylindrical. The internal dimensions of the cells and the manufacturing methods used in electrode-separator composite assemblies differ. The choice of cell design depends on a number of factors, such as optimizing filling efficiency, managing packaging considerations, addressing the electrical, thermal, and mechanical engineering requirements of the battery pack, meeting performance specifications, and considering cost constraints.

[0003] Among the first types of battery cells mass-produced, one remains prevalent in modern applications: the cylindrical cell. In a cylindrical cell, the terminals are located on opposite sides and are typically arranged in multiple rows. Battery pack assembly involves various methods, such as spring loading, welding techniques, adhesives, or wire bonding. Rigid spacers, spacers, or mounting brackets are commonly used to secure cylindrical cells within battery modules or packs. Adhesives are also a primary means of securing cylindrical cells, but this comes at the cost of increased battery pack size and complexity.

[0004] Cylindrical cells present several challenges in battery pack design. These challenges include the low fill density resulting from the circular cell cross-section, necessitating additional supports and contactors in high-capacity batteries, thus increasing complexity and weight. Uniform thermal management and heat dissipation across all cells have been found to be a significant challenge. Furthermore, thermal management issues are exacerbated by current concentration at the tabs and terminals, leading to localized cell degradation. This issue requires a trade-off between smaller cell form factors with superior thermal performance and larger cell form factors with higher energy density and cost efficiency.

[0005] Another type of battery cell, known as a pouch cell, is described, characterized by a sealed container constructed from flexible multilayer foil rather than a rigid outer shell. Pouch cells typically rely on a cell frame as their primary means of fixation. In this construction, the cells are inserted, redundantly sealed, and maintained under relaxed tension. The gaps between these cells provide opportunities for additional applications, such as enabling cooling systems.

[0006] Pouch cells require protection from external impacts and punctures, limiting their applicability in mechanical and industrial environments. Furthermore, pouch cells are prone to reversible and irreversible expansion, necessitating careful battery pack engineering to prevent cell compression and potential safety hazards. These cells can utilize electrodes in wound or stacked forms. Stacked electrodes further improve thermal engineering design but come with increased manufacturing complexity and associated costs, and sometimes raise safety concerns.

[0007] Another type of battery cell is the prismatic cell, which consists of a rectangular metal or rigid plastic casing. Prismatic cells come in two variations: single-row or double-row modules, with terminals located at the top or bottom of the casing. These cells are typically joined using various methods, including weld bonding, the use of busbars and support plates, or pull / form-fit connections via screwing or snap-fit, where perforated busbars act as bridging devices. An alternative to securing prismatic cells is adhesive bonding, which requires a lightweight and flexible adhesive medium to prevent cavitation.

[0008] Whether cylindrical or prismatic, the design and performance of battery cells are influenced by several key factors. Electrodes and separators located near the corners of the container may experience higher stress levels, potentially leading to faster degradation and safety issues. Additionally, for cuboid cells with metal casings, their higher filling efficiency results in densely packed battery packs, posing challenges to effective heat dissipation and thermal management. This accelerates performance degradation and shortens lifespan, especially in larger cells. Furthermore, prismatic cells face similar thermal management challenges to cylindrical cells, primarily due to current concentration at the terminals and tabs. Finally, employing a stacked electrode design introduces significant complexity into the manufacturing process.

[0009] Several key factors influence battery cell design and manufacturing. These include lower fill density, which affects energy storage capacity; thermal management challenges related to heat dissipation; increased manufacturing complexity leading to higher costs; difficulty in customizing cells to meet customer needs; and the complexity associated with achieving specific cell shapes.

[0010] CN110061168B discloses a cylindrical battery cell equipped with insulating elements (e.g., insulating rings, one or more insulating layers integrated in the shaft of a cylindrical battery, etc.), and a battery module including the battery cell. However, this invention has low fill density, low thermal management level, and high production cost and complexity.

[0011] US10476044B2 discloses alkaline or non-aqueous proton-conducting pouch cells that can be cycled without safety vents, thereby increasing energy density and battery design flexibility. However, this invention suffers from low fill density, poor thermal management, and high manufacturing costs and complexity.

[0012] Therefore, due to the aforementioned drawbacks, there is a need for a prismatic cell that can provide high fill density within a battery pack, achieve effective thermal regulation, and simplify the production process to reduce manufacturing costs. Summary of the Invention

[0013] The main objective of this invention is to provide a novel battery cell based on a prism structure, which allows for a high fill rate for battery packs.

[0014] Another object of the present invention is to provide a novel battery cell based on a prism structure, in which the battery cell terminals are electrically separated across the battery cell by the shortest possible distance.

[0015] Another object of the present invention is to provide a novel battery cell based on a prism structure, wherein the face with the largest area on the opposite side serves as the battery cell terminal.

[0016] Another object of the present invention is to provide a novel battery cell based on a prism structure, which allows current to be distributed over a large cross-sectional area, thereby preventing current concentration and hot spots.

[0017] Another object of the present invention is to provide a novel battery cell based on a prism structure, in which lower heat generation ensures that thermal management is not affected by the tight packing of the cell within the battery pack.

[0018] Another object of the present invention is to provide a novel battery cell based on a prism structure that eliminates the dependence of cell performance on battery size and shape, thereby allowing for larger cells without compromising cell performance.

[0019] Another object of the present invention is to provide a novel battery cell based on a prism structure, which allows for size freedom, thereby the battery cell can be made into any shape, not limited to rectangular or circular.

[0020] Another object of the present invention is to provide a novel battery cell based on a prism structure, which has low manufacturing cost and complexity, thereby improving the manufacturability of the battery per kilowatt-hour (kWh).

[0021] This invention relates to a novel battery cell based on a prism-shaped structure, which enables a high fill rate within a battery pack, thereby ensuring that the cell terminals are located at the shortest possible distance across the cell. Furthermore, despite the cell being tightly packed within the battery pack, this invention aims to minimize heat generation to maintain effective thermal management.

[0022] In one embodiment, the present invention provides a novel battery cell based on a prismatic structure. This novel prismatic structure-based battery cell includes a body and multiple layers assembled within the body. The body is prismatic and provides a maximum flat surface as a cell terminal when the prismatic body redirects current. The body includes an anode layer, a separator layer, a cathode layer, an adhesion layer, an upper current collector layer, and a lower current collector layer. The anode layer facilitates the inflow of a set of ions into the electrochemical battery cell based on a multidimensional electrode structure, and the anode layer includes multiple blind holes that increase the flow of this set of ions. The cathode layer provides a set of ions for embedding within the anode layer. The separator layer facilitates the flow of a set of ions between the anode and cathode layers to prevent electrical short circuits. The adhesion layer facilitates a set of electrical connections between the cathode layer and the upper current collector layer. The upper and lower current collector layers constitute a complete conductive circuit for the electrochemical battery cell based on the multidimensional electrode structure.

[0023] The above-described objects and advantages of the present invention will become apparent from the following description of the drawings, detailed description, and appended claims. Attached Figure Description

[0024] The novel battery cell based on a prism structure of the present invention can be understood by referring to the following figures.

[0025] Figure 1(a) is a top view of a novel battery cell based on a prism structure according to an embodiment of the present invention; Figure 1(b) is a side view of a novel battery cell based on a prism structure according to an embodiment of the present invention; and Figure 1(c) is a bottom view of a novel battery cell based on a prism structure according to an embodiment of the present invention.

[0026] Figure 2 This is an exploded view of a novel battery cell based on a prism structure according to an embodiment of the present invention. Detailed Implementation

[0027] The invention will now be described below with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. However, the invention may be embodied in many different forms and should not be construed as limited to the embodiments described herein. Rather, embodiments are provided so that this disclosure will be thorough and will fully convey the scope of the invention to those skilled in the art.

[0028] Many aspects of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale. Rather, the emphasis is on clearly illustrating the components of the invention. Furthermore, the same reference numerals denote corresponding parts throughout several views in the drawings. Before explaining at least one embodiment of the invention, it should be understood that embodiments of the invention are not limited in their application to the structural details and component arrangements set forth in the following description or shown in the drawings. Embodiments of the invention can be practiced and implemented in various ways. Additionally, the wording and terminology used herein are for descriptive purposes and should not be considered limiting.

[0029] This invention relates to a novel battery cell based on a prism-shaped structure, which enables a high fill rate within a battery pack, thereby ensuring that the cell terminals are located at the shortest possible distance across the cell. Furthermore, despite the cell being tightly packed within the battery pack, this invention aims to minimize heat generation to maintain effective thermal management.

[0030] In one embodiment, the present invention provides a novel battery cell based on a prismatic structure. This novel prismatic structure-based battery cell includes a body and multiple layers assembled within the body. The body is prismatic and provides a maximum flat surface as a cell terminal when the prismatic body redirects current. The body includes an anode layer, a separator layer, a cathode layer, an adhesion layer, an upper current collector layer, and a lower current collector layer. The anode layer facilitates the inflow of a set of ions into the electrochemical battery cell based on a multidimensional electrode structure, and the anode layer includes multiple blind holes that increase the flow of this set of ions. The cathode layer provides a set of ions for embedding within the anode layer. The separator layer facilitates the flow of a set of ions between the anode and cathode layers to prevent electrical short circuits. The adhesion layer facilitates a set of electrical connections between the cathode layer and the upper current collector layer. The upper and lower current collector layers constitute a complete conductive circuit for the electrochemical battery cell based on the multidimensional electrode structure.

[0031] Figure 1(a) is a top view of a novel battery cell based on a prismatic structure according to an embodiment of the present invention. This novel battery cell 100 based on a prismatic structure redirects current by changing its structure or geometry, and the prismatic shape provides a large flat surface as a battery cell terminal. Furthermore, the length (denoted by X) of the novel battery cell 100 based on the prismatic structure ranges from 12 mm to 400 mm, the width (denoted by Y) ranges from 12 mm to 300 mm, the thickness (denoted by Z) ranges from 5 mm to 20 mm, and further, the corner radius (denoted by R) ranges from 1 mm to 99 mm (as shown in Figure 1(c)). Further, the novel battery cell 100 based on a prismatic structure includes a body, which is a prismatic body, and when the prismatic body redirects current, it provides a maximum flat surface (as shown in A in Figure 1(a)) as a battery cell terminal.

[0032] Figure 1(b) is a side view of a prismatic battery cell according to an embodiment of the present invention. Furthermore, the prismatic shape of this novel battery cell based on a prismatic structure allows for a high fill rate value for the battery pack, and the cell terminals are separated across the cell with the shortest possible distance. In addition, the large flat surface of the cell terminals facilitates uniform current distribution across the entire surface area, thereby alleviating concerns related to current and heat concentration.

[0033] Figure 1(c) is a bottom view of a novel battery cell based on a prismatic structure according to an embodiment of the present invention. The lower heat generation characteristics of this novel prismatic structure-based battery cell 100 ensure that thermal management remains unaffected even when the cell is tightly packed within a battery pack. Furthermore, the prismatic shape allows larger cells to exhibit similar thermal management and power performance capabilities as smaller cells. Additionally, the prismatic shape helps reduce manufacturing costs and complexity, ultimately improving cell manufacturability per kilowatt-hour (kWh) of battery output.

[0034] The novel battery cell 100 based on a prismatic structure is arranged in a stacked configuration. Further, the prismatic battery cell includes multiple layers, including a lower current collector layer, an anode layer, a separator layer, a cathode layer, an adhesion layer, and an upper current collector layer. The anode layer is placed above the lower current collector layer, and the separator layer is located above the anode layer. Further, the cathode layer is placed above the separator layer. The separator layer facilitates the flow of lithium ions between the anode and cathode layers, thereby preventing short circuits. Additionally, an adhesion layer is applied to the upper surface of the cathode layer, and a conductive layer, acting as the upper current collector, is located on top of the adhesion layer. The adhesion layer facilitates one or more electrical connections between the cathode layer and the upper current collector layer. Further, to ensure a complete conductive circuit, a conductive component, acting as the lower current collector, is fixed to the bottom surface of the anode layer. This arrangement of multiple layers forms a multidimensional electrode battery cell.

[0035] refer to Figure 2 An exploded view of a battery cell 100 based on a prismatic structure is shown. The prismatic structure-based battery cell 100 includes an anode layer 1, a separator layer 2, a cathode layer 3, an adhesion layer 4, an upper current collector layer 5, and a lower current collector layer 6. The anode layer 1 facilitates the inflow of a set of ions into the electrochemical battery cell 100 based on a multidimensional electrode structure, and the anode layer 1 includes multiple blind holes that increase the flow of these ions. The depth of the multiple blind holes is 0.1 mm to 2 mm less than the height of the anode layer 1. The inner surface of the multiple blind holes is coated with a separator material. The multiple blind holes are filled with lead-shaped cathode material. The multiple blind holes ensure that the lead-shaped cathode material moves through the anode layer 1.

[0036] The pin-shaped cathode material consists of a predefined number of cathode active material powders that allow the transport of multiple ions without altering the kinetic values.

[0037] The cathode layer 3 provides a set of ions that are embedded in the anode layer 1. The diaphragm layer 2 facilitates the flow of these ions between the anode layer 1 and the cathode layer 3 to prevent electrical short circuits.

[0038] A membrane layer 2 is sandwiched between the cathode layer 3 and the anode layer 1. The thickness of the membrane layer 2 ranges from 5 to 150 micrometers. The membrane layer 2 is composed of ceramic powder.

[0039] The adhesion layer 4 facilitates a set of electrical connections between the cathode layer 3 and the upper current collector layer 5. The upper current collector layer 5 and the lower current collector layer 6 constitute a complete conductive circuit of the electrochemical cell 100 based on a multidimensional electrode structure. The upper current collector layer 5 is fixed to the upper surface of the adhesion layer 4. The lower current collector layer 6 is fixed to the bottom surface of the anode layer 1.

[0040] The adhesion layer 4 is sandwiched between the cathode layer 3 and the upper current collector layer 5.

[0041] Anode layer 1, diaphragm layer 2, cathode layer 3, upper current collector layer 5, adhesion layer 4, and lower current collector layer 6 are fixed to each other by at least one of mechanical contact process and deposition process.

[0042] Example 1 Experimental Analysis This invention provides a novel battery cell based on a prismatic structure, which increases the fill efficiency by 7% to 10%. In conventional battery cells, active energy storage materials account for only 59% of the cell volume, while inactive components (electrolyte, separator, binder, conductive additives, current collector, etc.) occupy the remainder. In this invention, by eliminating the current collector film, the volume occupied by the active material increases to 65%, or the fill efficiency increases by 7% to 10%.

[0043] Furthermore, the shortest distance for terminal separation across the cell can range from 7 mm to 20 mm.

[0044] Furthermore, compared to conventional battery cells, heat generation is reduced by 90%. Furthermore, fast charging time is reduced to 12 minutes (0-80%). Similarly, the temperature rise caused by fast charging is reduced from 16-25°C (observed in conventional battery cells) to 2-3°C. In addition, the structure of this invention significantly improves fire safety, enhances the temperature stability of the battery cell (the temperature at which the cell spontaneously combusts), and prevents the battery cell from entering a state of thermal runaway (due to the stable properties of the ceramic separator).

[0045] Therefore, this invention provides a novel battery cell based on a prism-shaped structure, which enables a high fill rate within the battery pack, thereby ensuring that the cell terminals are located at the shortest distance across the cell. Furthermore, despite the cell being tightly packed within the battery pack, heat generation is minimized to maintain effective thermal management.

[0046] Many modifications and other embodiments of the invention described herein will readily occur to those skilled in the art upon benefit from the teachings presented in the foregoing description and the accompanying drawings. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terminology is used herein, it is used only in a general and descriptive sense and not for limitation.

[0047] The foregoing description of embodiments of the present invention is presented for illustrative and descriptive purposes. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed, and modifications and variations are possible or may be obtained from practice of the invention in light of the foregoing teachings. The embodiments were chosen and described to explain the principles of the invention and its practical application, enabling those skilled in the art to apply the invention in various embodiments with various modifications contemplated for a particular purpose.

Claims

1. A battery cell (100) based on a prism structure, comprising: main body; Multiple layers assembled inside the main body; in, The main body is a prismatic body. When the prismatic body redirects the current, the prismatic body provides the largest flat surface as a cell terminal. The main body comprises an anode layer (1), a diaphragm layer (2), a cathode layer (3), an adhesion layer (4), an upper current collector layer (5), and a lower current collector layer (6). The anode layer (1) facilitates the inflow of a set of ions into the electrochemical cell (100) based on the multidimensional electrode structure, and the anode layer (1) includes a plurality of blind holes, which increase the flow of the set of ions; The cathode layer (3) provides a set of ions, which are then embedded in the anode layer (1); The membrane layer (2) facilitates the flow of the group of ions between the anode layer (1) and the cathode layer (3) to prevent electrical short circuits. The adhesion layer (4) facilitates a set of electrical connections between the cathode layer (3) and the upper current collector layer (5); and The upper current collector layer (5) and the lower current collector layer (6) constitute the complete conductive circuit of the electrochemical cell (100) based on the multidimensional electrode structure.

2. The battery cell (100) based on a prism structure according to claim 1, wherein, The length of the prism-based cell (100) ranges from 12 mm to 400 mm, the width ranges from 12 mm to 300 mm, the thickness ranges from 5 mm to 20 mm, and the corner radius ranges from 1 mm to 99 mm.

3. The battery cell (100) based on a prism structure according to claim 1, wherein, The cell terminals are separated across the prism-structure-based cell (100) by a predefined distance.

4. The battery cell (100) based on a prism structure according to claim 1, wherein, The anode layer (1), the diaphragm layer (2), the cathode layer (3), the upper current collector layer (5), the adhesion layer (4), and the lower current collector layer (6) are fixed to each other by at least one of mechanical contact process and deposition process.

5. The battery cell (100) based on a prism structure according to claim 1, wherein, The depth of the plurality of blind holes is 0.1 mm to 2 mm less than the height of the anode layer (1).

6. The battery cell (100) based on a prism structure according to claim 1, wherein, The inner surfaces of the plurality of blind holes are coated with diaphragm material.

7. The battery cell (100) based on a prism structure according to claim 1, wherein, The multiple blind holes are filled with pin-shaped cathode material.

8. The battery cell (100) based on a prism structure according to claim 1, wherein, The multiple blind holes ensure that the pin-shaped cathode material moves through the anode layer (1).

9. The battery cell (100) based on a prism structure according to claim 1, wherein, The pin-shaped cathode material is composed of a predefined number of cathode active material powders, which allow the transport of multiple ions without altering the kinetic values.

10. The battery cell (100) based on a prism structure according to claim 1, wherein, The diaphragm layer (2) is sandwiched between the cathode layer (3) and the anode layer (1).

11. The battery cell (100) based on a prism structure according to claim 1, wherein, The thickness of the membrane layer (2) ranges from 5 to 150 micrometers.

12. The battery cell (100) based on a prism structure according to claim 1, wherein, The diaphragm layer (2) is composed of ceramic powder.

13. The battery cell (100) based on a prism structure according to claim 1, wherein, The adhesion layer (4) is sandwiched between the cathode layer (3) and the upper current collector layer (5).

14. The battery cell (100) based on a prism structure according to claim 1, wherein, The upper current collector layer (5) is fixed on the upper surface of the adhesive layer (4).

15. The battery cell (100) based on a prism structure according to claim 1, wherein, The lower current collector layer (6) is fixed to the bottom surface of the anode layer (1).

16. The battery cell (100) based on a prism structure according to claim 1, wherein, The electrochemical cell (100) based on the multidimensional electrode structure achieves an energy density increase in the range of 25% to 33%.

17. The battery cell (100) based on a prism structure according to claim 1, wherein, The anode layer (1), the diaphragm layer (2), the cathode layer (3), the adhesion layer (4), the upper current collector layer (5), and the lower current collector layer (6) have a flat contact surface shape.

18. The battery cell (100) based on a prism structure according to claim 17, wherein, The flat contact surface provides a high fill rate for the battery cell.

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