Battery Cell Sealing Layout for Smooth Degassing and Leak Prevention

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery cell manufacturing methods face issues with gas discharge inefficiency, leading to potential damage to the sealed portion, insulation failure, and electrolyte leakage due to protrusions in the sealed portion, which hinder smooth gas flow and increase the risk of leakage.

Innovation Solution

A method involving edge sealing, finishing sealing, and degassing processes to form a battery cell with specific edge and exterior sealed portions, including chamfered extensions and overlapping designs to facilitate smooth gas discharge and prevent damage, thereby reducing insulation failure and leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a protrusion is formed in the sealed portion at the corner of the electrode accommodation portion, then the sealed portion can be folded to reduce battery cell volume, but gas flow from the electrode accommodation portion to the gas accommodation portion is impeded

Engineering Contradiction:

Improvebattery cell volumeVSAvoidgas discharge efficiency

Core Design Contradiction:

Volume of moving objectVSProductivity

Solution Approach 1:

The sealed portion is divided into multiple sealing regions: a first sealing region extending from the electrode accommodation portion edge, and a second sealing region extending from the gas accommodation portion edge. These segmented sealing regions eliminate the protrusion that would impede gas flow while maintaining the folded structure for volume reduction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the sealed portion are designed with different properties: the first sealing region is optimized for sealing the electrode accommodation portion, while the second sealing region is optimized for sealing the gas accommodation portion. This local differentiation allows gas to flow smoothly through the boundary without encountering a protrusion obstacle, while still achieving volume reduction through folding.

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If the sealed portion is folded to reduce battery cell volume, then compactness is improved, but insulation failure or leakage may occur

Engineering Contradiction:

Improvebattery cell volumeVSAvoidsealed portion integrity

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The overlapping portion is designed with sufficient overlap area between the first and second sealing regions before folding occurs. This pre-designed overlap provides a buffer zone that maintains sealing integrity and prevents insulation failure during the folding process and throughout the battery cell's operational life.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The first sealing region and second sealing region are merged through an overlapping portion that extends beyond the boundary between electrode accommodation portion and gas accommodation portion. This merging creates a redundant sealing structure that prevents leakage and maintains reliability even when the sealed portion is folded to reduce volume.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If gas flow path is obstructed by protrusion in the sealed portion, then sealing structure is simplified, but damage to the sealed portion and electrolyte leakage risk increase

Engineering Contradiction:

Improvesealed portion structureVSAvoidsealed portion durability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Instead of forming a protrusion that extends into the gas flow path, the invention inverts the approach by creating sealing regions that extend along the boundary without protruding into the gas flow path. The first sealing region extends from the electrode accommodation portion edge and the second sealing region extends from the gas accommodation portion edge, meeting or overlapping at the boundary without creating an obstructive protrusion.

Inventive Principle:

Principle #13The other way round (Inversion)

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 method ensures efficient gas discharge, prevents damage to the sealed portion, and minimizes insulation failure and electrolyte leakage, enhancing the reliability and safety of the battery cell.

Implementation Method 1

The sealed portion may be formed by thermally fusing (compressing) an internal layer of the case

Methodology Applied

Scientific EffectThermal fusion: Heating

Data Source

PatentUS20260066511A1Method of manufacturing battery cell and battery cell

Publication Date: 2026.03.05 SK ON CO LTD

AI summary

A method of manufacturing a battery cell includes an edge sealing process of sealing at least a portion of an edge of a case to form an edge sealed portion blocking an electrode accommodation portion and a gas accommodation portion externally and a finishing sealing process of sealing a boundary portion crossing between the electrode accommodation portion and the gas accommodation portion in a first direction to form an exterior sealed portion, wherein the exterior sealed portion includes a first portion formed in a central region of the boundary portion and a second portion formed in an end region of the boundary portion, and in the finishing sealing process, an extension extending in a second direction toward the electrode accommodation portion is formed in the second portion of the exterior sealed portion.