High-Capacity Battery Cell Grouping for Consistent Parallel Packs

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Solution Overview

Problem

Existing high-capacity lithium batteries suffer from poor consistency, unstable performance, and high rejection rates due to improper connection and alignment of battery cells, leading to issues like overheating and overcharge, with separate electrolyte filling resulting in poor overall performance.

Innovation Solution

A manufacturing method involving battery cell formation and capacity grading after primary electrolyte injection, grouping cells by performance parameters, connecting them in shunt, and performing secondary electrolyte injection into a high-capacity battery pack, followed by sealing and aging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a number of groups of battery cells are connected in shunt to achieve high capacity, then the battery capacity increases, but the consistency among battery cells deteriorates due to performance differences

Engineering Contradiction:
Improvebattery capacityVSAvoidconsistency among battery cells
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent applies preliminary action by performing formation and capacity grading of battery cells before they are connected in shunt to form high-capacity batteries. This pre-grading process ensures that only cells with consistent performance parameters (capacity, internal resistance, voltage, self-discharge rate) are grouped together, thereby maintaining high consistency in the final high-capacity battery while achieving the desired high capacity through parallel connection.

Inventive Principle:
Principle #10Preliminary action

2Quantity of substance

If battery cells are connected in shunt without proper grading, then high capacity is achieved, but performance stability deteriorates due to quality defects

Engineering Contradiction:
Improvebattery capacityVSAvoidperformance stability
Core Design Contradiction:
Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The patent implements preliminary action by conducting formation and comprehensive quality grading of battery cells before assembling them into high-capacity battery packs. This pre-screening process identifies and separates cells with quality defects or performance deviations, ensuring that only cells meeting strict consistency criteria are connected in shunt. This preliminary grading action guarantees both high capacity and stable performance throughout the battery's operational life.

Inventive Principle:
Principle #10Preliminary action

3Ease of manufacture

If separate electrolyte filling is used in existing high-capacity lithium batteries, then manufacturing simplicity is maintained, but overall performance deteriorates

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidoverall performance
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent applies the merging principle by combining the electrolyte filling operations for multiple battery cells into a single unified process. Instead of separately filling electrolyte into each individual cell, the patent designs a common electrolyte cavity that accommodates multiple battery cells, allowing one electrolyte filling operation to serve all cells simultaneously. This merging approach maintains manufacturing simplicity while ensuring consistent electrolyte distribution and improving overall battery performance.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS12537253B2High-capacity battery manufacturing method and high-capacity battery
Publication Date: 2026.01.27 AMERICA NAT POWER STORAGE LLC
  • US12537253B2 patent drawing
  • US12537253B2 patent drawing
  • US12537253B2 patent drawing

AI summary

Disclosed are a high-capacity battery manufacturing method and a high-capacity battery, which mainly solve the problems of poor consistency, unstable performance and poor overall working performance of existing high-capacity lithium batteries. The method comprises: assembling coiled or laminated units that make up high-capacity battery cells into battery cells individually, carrying out formation and capacity grading of the battery cells, grouping the battery cells according to one or more of their capacity, internal resistance, voltage and self-discharge, connecting the battery cells in the same group in shunt, loading the battery cells in the same group into a high-capacity battery pack, and then carrying out secondary electrolyte injection, sealing, aging and capacity grading of the high-capacity battery pack. According to the present application, battery cell formation and capacity grading are carried out after primary electrolyte injection.