Large-Sized Flat Cells/Batteries TRIZ Cases

Rotationally symmetrical sub-modules simplify high-cell-count battery assembly, cutting build time and weight while preserving stable connections.

Varying active material layer thickness across stacked electrodes helps balance battery energy density, output performance, and current flow.

Alternating adhesive coating weights and cut placement suppress separator peeling and curling in secondary battery laminates.

Pre-formed bus bar holes let straight battery tabs be inserted and welded, cutting bending steps, assembly cost, and tab deformation.

Protruding separators are heat-bonded and folded back to hold cell alignment, prevent shorts, and limit assembly width.

Segmented resin sealing members and spacers absorb detection-line thickness while limiting current collector deformation and sealing defects.

A joined resin seal and welded laminate structure stabilizes communication-hole sealing while allowing electrolyte filling without leakage.

Selective resin removal exposes facing metal layers at tab regions, enabling low-resistance energization and secure lead fixation in battery electrodes.

A top cover protrusion blocks weld laser leakage and falling particles from reaching the electrode assembly inside the battery cell.

Thermally conductive brackets and insulation pads cool tightly stacked pouch cells while improving protection and avoiding coolant leakage.

A molded separator protrusion balances drop resistance and electrolyte impregnation in a wound battery while reducing leakage risk.

A recessed packaging bag creates concave space for tabs and conductive parts, raising battery cell energy density while limiting contact and leakage risk.

Inward-pinched case walls restrain electrode movement while preserving expansion space and gaps for electrolyte entry and gas escape.

An elastic concave-convex retainer fills case gaps to ease electrode insertion while preventing assembly movement and damage.

An insulating coating on the adjacent electrode slit surface blocks tab-end short circuits while preserving stack shape and simpler processing.

A split outer film and cap structure avoids pouch-film molding cracks, increases cell capacity, and helps block moisture ingress.

Sequential fixing and bending of an electrode lead distributes tensile stress and prevents tab joint disconnection in battery manufacturing.

A side-mounted retainer secures thin insulating members in a secondary battery, preserving internal space, insulation, and assembly stability.

Step relief tape removes fixing-tape edge steps so stack cells maintain uniform laminate pressure and avoid separator gaps and lithium precipitation.

Thermal fusion of a conductive polymer-film current collector seals unit electrodes, blocking electrolyte migration without added sealing layers.

Slits in the battery collector vent trapped air during lamination, reducing delamination and structural defects in thin or large-area cells.

Alternating adhesive coating weights keep battery separators bonded during cutting while avoiding edge buildup on cutting tools.

Asymmetric electrode spacing reduces active material near the vent wall, lowering pull on the pressure relief structure and leakage risk.

Positioning bulges and a detachable hold-down beam keep long battery tabs aligned during folding to prevent insertion and short circuits.

Offset cathode and anode tabs split welding into smaller steps, improving weld reliability while supporting high electrode counts and power density.

Rolling pressure induces temporary shorts at separator defects, enabling low-voltage leakage-current detection and precise damage localization.

Asymmetric inner and outer connection plates cut internal resistance, limit local degradation, and free space for battery-pack electronics.

A porous conductive deformation-absorbing member lets electrodes expand and contract without deforming the battery case or adding module support.

A localized pressure compensation member evens pouch-cell pressure at low-thickness regions to limit swelling, resistance rise, and capacity fade.

A recessed case bottom forms cooling channels between adjacent secondary cells, improving heat dissipation without enlarging the module.

A recessed case bottom and fitted electrode assembly improve battery cooling, raise energy density, and reduce module stacking height.

A through-hole fixing member secures the electrode assembly in thickness direction to suppress swelling, improve adhesion, and reduce short-circuit risk.

Through holes and positioning pins align stacked battery cells accurately, then invalid zones are cut away to raise energy density and lower cost.

A high-strength protective member around the electrode terminal limits movement, prevents insulating member cracking, and improves cell reliability.

A through-hole and fixing member restrain electrode assembly swelling while preserving gas release, insulation, and short-circuit protection.

Through holes and positioning pins align stacked battery cells quickly, then invalid zones are cut away to raise energy density and lower fixture cost.

A polymer-metal composite substrate and conductive fixing members cut battery weight while preserving electrode stability and safety.

Composite electrode substrates cut battery weight while conductor tabs joined at non-coated regions improve connection stability and safety.

Active materials are coated on both sides of separator sheets to keep electrode alignment and anode overhang consistent, reducing short-circuit risk.

Elastic biasing members and supporting portions keep battery cells aligned despite deformation variation, reducing terminal deviation, size, and weight.

A concave-convex electrode assembly uses bonding space more efficiently in prismatic lithium-ion cells, reducing empty volume and raising energy density.

Current collectors tuned for strength and ductility enable simultaneous multi-layer bipolar battery lamination without cracking or loose layer connections.

A welded folded double-tab structure reinforces thin battery electrode tabs, preventing roller-induced bending and damage during lamination.

An outward extension on the first electrode enables accurate stacked-gap measurement while allowing wider uncoated portions to prevent island defects.

A fluid-filled intermediate member equalizes restraint load across stacked battery modules even when end plates bend, improving structural stability.

A horizontal plate layout in a 12 V VRLA AGM battery limits electrolyte stratification and plate deformation, extending cyclic life.

Interchangeable sub-housings with protruding and recessed couplings let one battery stack plate platform fit varied wire directions and stack specs.

Segmented bonding leaves a gap between the battery cell and case to absorb expansion stress, improving energy density and thermal safety.

Linking battery modules through end plates and restraint members cuts pack housing weight, simplifies installation, and improves impact resistance.

Independent single-stack pouch cells isolate defects, avoid welding contamination, and lower electrolyte fire risk in battery manufacturing.

Pre-joined stacked metal plates let a battery current collector bend between joined regions while suppressing tab group damage during assembly.

Invisible-light laser scanners target road areas at risk of black ice, reducing salt use, corrosion, and wasted deicing energy.

Invisible-light laser scanners use weather and surface sensing to heat only icy road zones, avoiding salt contamination and buried wire costs.

Springs between battery cell stacks absorb expansion and tighten assembly tolerance, improving module reliability and temperature monitoring.

S-shaped folded bipolar electrodes remove tabs, busbars, and punching steps to cut contamination and short-circuit risk while improving space use.

Parallel-connected unit cells with solid electrolytes and separating frames raise output voltage and energy density while simplifying battery safety design.

Side-wall terminal orifices enable stackable battery cell assembly, cutting interconnect parts, saving space, and protecting current collectors.

Protruding separators are folded and heat-bonded to hold stacked cells in place, reducing misalignment and direct electrode short-circuits.

Staggered fixing tape winding on adjacent battery cells cuts stack thickness while preserving fixation and improving volumetric efficiency.

Direct bipolar-plate connections between adjacent cells remove terminal posts and bus bars, cutting battery pack weight, volume, and heat.

A metal-foil side surface member shields the resin sealing member during outer-package welding, preventing deformation and wrinkles.

Bonding parts block electrolyte impact at vulnerable separator regions, preventing drop-induced shrinkage while preserving energy density.

A multi-part swaging die forms stronger battery interlocks that resist vibration and impact while avoiding foreign matter generation.

A positioning part overlapping the terminal through-hole holds the crimp in place, reducing deformation from vibration and impact.

An insulative coating wrapped around a negative-electrode shoulder prevents lamination contact, short circuits, and overhang reversal.