Final Product Manufacture TRIZ Cases

Crosslinked polypropylene or polyethylene inner resin improves pouch-cell sealing force and insulation, reducing cracks, venting, and material use.

A bonded or force-fitted processing pin lets ultrasonic sonotrodes reach difficult weld points while cutting custom length and material costs.

A groove in the internal element stores part of the laminate outer package, preventing sealing wrinkles and preserving sealability over time.

Sequential lower-to-upper pressing with foldable plates directs residual gas to the pouch cell gas pocket and suppresses gas trapping.

Controlling anode current collector creep helps jelly-roll electrodes absorb silicon-driven stress, limiting swelling and internal disconnection.

A recessed holder with elastic support fixes the temperature sensor at a uniform cell distance, improving battery pack temperature accuracy and safety.

Plate-shaped silicate in a separator coating slurry improves dispersion and phase stability, creating a more uniform layer that helps prevent shorts.

A cyclical station-based deposition process builds stacked 3D battery cells on a substrate, improving scalability while managing layer complexity.

Lowering negative electrode core proof stress to 300 MPa or less preserves winding length and boosts charge-discharge capacity.

Perforations in a laminated foil electrode improve electrolyte distribution and Li+ transport while reducing metal burring and shorting.

A thinner uncoated electrode region and insulating layer placement free more cell space, cut tab overlap resistance, and improve battery capacity.

Inner wall groove regions absorb electrode expansion in a secondary battery case, reducing pressure, cracks, and short-circuit risk.

Collapsing the electrode tab emboss before staged waveform welding increases current carrying area and improves battery case joint reliability.

Cut-out insulating tape preserves a gas discharge path in lithium secondary battery electrode assemblies, reducing pressure buildup during thermal events.

Band-gap tuning, lattice matching, and a Bragg reflector raise space solar cell efficiency while preserving radiation resistance over life.

A dual-separator electrode assembly pairs ionic conductivity with bonding strength to improve battery cycle life and short-circuit safety.

A grooved central structure joins battery case halves without welding, reducing electrode damage while improving space use and energy density.

A metal-sheet bridge and dual bonding marks connect laminated current collectors without folding, cutting resistance while improving battery output and productivity.

Optimized pouch-cell edge radius and housing thickness improve sealing integrity, prevent film breakage, and preserve energy density.

An EVA-based protective film stays bonded to pouch battery tab-lead welds during electrolyte wetting, preventing folding and insulation issues.

An intermediate layer between the collector and active material suppresses thick edge buildup and improves electrode adhesion.

Offset bonding marks between a metal sheet and electrode tab cut connection resistance and simplify laminate assembly in lithium secondary batteries.

A locally thinned positive electrode layer relaxes winding-side stress, limiting plate deformation and reducing insulation needs in secondary batteries.

Local reinforcement near the bending segment keeps thin electrode plates aligned, reducing wrinkles, yield loss, and lithium precipitation.

A pouch-cell formation sequence uses degassing and CC/CV discharge to limit deformation, shorten processing, and improve capacity reliability.

Segmented isochoric and isobaric double belt pressing speeds bipolar plate production while preserving thin structures and precise geometry.

A multilayer passivation stack tunes refractive index and layer thickness to cut internal reflection and improve short- and long-wavelength absorption.

A dual-cap cell structure increases electrode assembly size while shortening cap-plate welding and directing vent discharge downward.

A framed grid of smaller substrate trays enables maglev-compatible unit handling, cutting large-tray cost, sagging, and transfer complexity.

Layered soft media and pressure sensing even out pouch-cell compression, reducing dendrite risk and improving current density uniformity.

A resistive polymer adhesive melts at a transition temperature to raise busbar resistance and limit current before battery thermal runaway spreads.

Monocrystalline layered cathode material and a 2.0-10.5 cell aspect ratio improve electrolyte infiltration, ion transport, and cycle life.

A resin guide component shields detection lines from mold contact during filling, improving module sealability without line damage.

Removing the negative active material layer improves cylindrical battery energy density, lowers heat generation, and simplifies manufacturing.

An oxygen-blocking member lets gel electrolyte cure fully in ambient air, preventing volatilization and separation in large electrode laminates.

A segmented pouch casing with an adhesion side and perpendicular extension cuts sealing volume while enabling more effective cooling.

A ceramic-coated microporous separator forms a protective interfacial layer to improve Li-ion battery safety, cycle life, and heat stability.

Higher silicon content in the outer negative electrode cuts curling during stacking, improving alignment, yield, and battery capacity.

A stepped insulating layer on the bent current collector side prevents detachment, foreign matter, and short-circuit risk in wound batteries.

A widened connecting space improves electrolyte flow into the electrode assembly, reducing trapped gas and enabling uniform impregnation.

A shortened current collecting tab with an overlapping dummy tab balances winding rigidity and helps prevent separator piercing and short-circuits.

Cooling and pressing lithium electrode tabs before ultrasonic welding prevents sticking, raises stiffness, and improves lead-tab coupling quality.

A mixed foil collection layout joins one electrode to a single terminal and splits the other, simplifying connections while raising energy density.

Surface-modified layers on manifold openings and surfaces improve fuel cell separator corrosion resistance while maintaining conductivity.

In-situ polymerization below 40°C preserves electrolyte additives while the gel thermally cures to block gas diffusion during battery runaway.

A two-separator jelly-roll layout cuts thickness and tab overlap to improve space utilization and energy density in electrochemical cells.

Mesh current collectors at the outermost stacked electrodes reduce irreversible capacity and raise lithium battery energy density.

Controlled separator openings and conductive filling create uniform internal short circuits for more reliable battery safety evaluation.

Localized heat and pressure improve bonding uniformity in zigzag electrode assemblies without over-compressing separators or raising resistance.

A folded sealed portion fits into a stepped pouch-cell indentation to cut unused space, maintain thickness, and improve leak-safe packaging.

Controlling battery-to-element thickness ratio keeps electrolyte from pooling or depleting, improving charge uniformity and cycle life.

A moving terminal safety valve releases battery-cell pressure and gas while a welded or soldered contact resists loosening and corrosion.

Strategically placed package holes vent charging gases from a semi-solid electrochemical cell, limiting capacity loss and short-circuit risk.

Lower surface electrodes and a multilayer coating reduce connection stress and block gas infiltration in mounted solid-state batteries.

A side-opening case lets larger electrode assemblies slide in laterally, improving prismatic battery assembly while preserving capacity and insulation.

A core-shell nickel gradient keeps high Ni in the particle core and lowers it in the shell to stabilize large cathode precursors and battery heat behavior.

A monocrystalline cathode and controlled cell aspect ratio improve electrolyte infiltration, limiting side reactions while extending cycle life.

Varying active material in the outermost and inner electrode layers balances charge-discharge reactions without a current collector.

Shifted insulating member ends on exposed positive-electrode portions reduce separator stress, short-circuit risk, and step formation.

Argon plasma treatment on pouch sealing and temporary adhesion regions improves seal strength and prevents insulation defects in secondary batteries.

A segmented pouch case with a recessed sheet and sealing member accommodates larger electrode assemblies while improving precision and energy density.

An overlapped upper-lower case with bonded insulation and an inward hook preserves battery capacity while improving sealing and impact resistance.

A three-side sealing layout with an adhesion edge and extending portions reduces pouch cell volume while enabling perpendicular cooling and stable sealing.

A localized barrier layer in electrode bend regions blocks electron transport, reducing lithium plating while preserving battery energy density.

An adhesive strip along the diffusion layer cut edge secures loose fibers, reducing membrane damage and short-circuit risk in electrochemical cells.

Varying electrode thickness and binder ratio by region improves winding durability and structural stability in secondary batteries.

Angled blank foil and notched corners enable top edge folding and sealing in pouch batteries without wrinkles, while preserving active area.

Overlapping notched electrode tabs cut non-coating area while lowering resistance and strengthening can-bonded connections.

Alternating inner and outer bent flag portions create multiple contact points, improving current collection plate welding quality and reducing defects.

Overlapped electrode assemblies and stacked current collectors strengthen tab connections to raise battery energy density and reliability.

A gasket with a central opening seals the second electrode, distributes compression evenly, and protects solid-state battery components from leakage.

Markers on battery electrode tabs encode orientation and stacking order, enabling automated alignment with fewer production errors and less material loss.

Repeated press-release immersion drives electrolyte quickly into large wound electrode bodies, cutting permeation time and limiting damage.

A high-pH water-based cathode coating uses an interfacing layer to improve adhesion and conductivity while cutting solvent recycling cost and fire risk.

Using trigonal lithium nickel oxide as a cathode irreversible additive limits structural change, reducing impurity and gas generation.

Controlled nanoscale cracking in carbon-coated cathode particles boosts lithium-ion capacity while preserving structural stability and cycle life.

A curved-edge protection member in a wound electrode assembly relieves jelly-roll stress, preventing substrate cracks and preserving insulation.

Chamfered electrode tab edges buffer movement inside the cell, reducing cap and insulator damage that can trigger internal short circuits.

Carbon black in graphite voids and on particle surfaces preserves conductive paths, reducing peeling-related battery durability loss.

A folded or rolled pouch-case expansion section cuts adhesive use, improves heat dissipation, and preserves battery durability and energy density.

Straight tab stacking in the axial direction avoids bending stress during collector connection, reducing tab breakage and improving battery yield.

Adding up to 10 wt% fullerene or carbon nanotubes to amorphous electrode carbon lowers resistance and raises LFP battery discharge energy.

A segmented current collector links the electrode assembly to the terminal through the sealing plate to improve battery energy density and reliability.

Thin metal layers on a polymer substrate cut collector volume while maintaining conductivity, helping secondary batteries raise energy density.

A bent disconnection preventing layer keeps the negative electrode current collector electrically connected despite crack-inducing battery expansion.

Yttrium fluoride particles sized 1-7 μm help NiMH negative electrodes suppress corrosion while preserving low-temperature discharge reactivity.

Asymmetric separator bonding relieves corner stress in wound Li-ion cells, improving electrolyte infiltration and suppressing lithium plating.

An uneven terminal surface and region-specific protrusions balance ultrasonic joining wear, suppress joint-boundary cracks, and keep battery connections strong.

Elongate protrusions create a gas exhaust groove during current collector laser welding, preventing blowholes and strengthening battery joints.

Varying active material capacity between electrode center and edge regions helps suppress lithium plating and improve battery safety.

A redox shuttle electrolyte balances cell capacity differences and suppresses overcharge at high current for stable cycling in cell packs.

Mixed cathode particles and a difluorophosphite electrolyte additive curb phase change, gassing, and swelling in high-voltage lithium cells.

Thermoplastic blocking portions bond separators and electrode tabs to restrain tab movement and prevent vibration-induced internal short circuits.

By removing outer plain aluminum foil and bonding the core to the package, this wound battery layout cuts impact-driven short-circuit risk.

Pre-assembling electrode plate groups with a separator forms a composite cell group, cutting Z-folding steps and boosting laminated cell output.

Phosphorus-doped isolation grooves weaken carrier drift between P- and N-type back-contact regions, cutting internal losses and improving conversion efficiency.

An angled single-camera setup captures battery cell side and lower surfaces in one image, cutting rotation hardware, space, and cost.

A coated lithium battery separator uses a heat-resistant filler layer and mixed fluorinated adhesives to cut membrane resistance and thermal shrinkage.

Acrylic and inorganic dual-layer coating improves electrode adhesion while preserving separator porosity and thermal shrinkage resistance.

A ceramic-coated microporous polyolefin separator limits shrinkage above 120°C and suppresses interfacial reactions to improve battery safety and cycle life.