Battery Cell Packaging Recess for Higher Energy Density
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Solution Overview
Problem
Current battery cell structures face challenges in maximizing energy density due to space inefficiencies, particularly at the ends where electrode tabs and conductive members are located, leading to wasted space and limited capacity.
Innovation Solution
The battery cell design incorporates a packaging bag with a recessed second portion forming a concave portion, allowing for a more compact structure by accommodating additional components and increasing the energy density by optimizing the dimensions and positions of electrode plates and conductive members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the packaging bag is made compact to reduce space occupancy, then energy density increases, but the risk of material contact and leakage increases
Solution Approach 1:
The packaging bag is divided into a first portion and a second portion, with the second portion recessed relative to the first portion. This segmentation creates distinct functional zones: the first portion accommodates electrode plates and conductive members with adequate clearance, while the second portion provides sealed containment. The segmented structure reduces overall space occupancy while maintaining safety clearances that prevent material contact and leakage.
Solution Approach 2:
The second portion of the packaging bag is nested within the projection of the first portion, creating a compact hierarchical structure. The electrode plates and conductive members are nested within the first portion, while the second portion provides an additional nested sealing layer. This nested arrangement maximizes space utilization while maintaining proper clearance between components to prevent harmful contact.
2Productivity
If electrode plates and conductive members are positioned to maximize capacity utilization, then energy density increases, but the risk of active material coating contact with electrode plate increases
Solution Approach 1:
The first portion of the packaging bag provides a localized safe environment with adequate clearance between the first electrode plate and conductive members. This local quality control ensures that even when components are positioned to maximize capacity utilization, the clearance in this specific zone prevents active material coating from contacting the electrode plate, thereby eliminating the harmful effect while maintaining high energy density.
3Volume of stationary object
If the second portion is recessed to form concave portion for accommodating other components, then energy density increases, but manufacturing complexity increases
Solution Approach 1:
The packaging bag is constructed from flexible packaging films that can be formed into the required shape with the second portion recessed relative to the first portion. This flexible shell structure allows the creation of the concave configuration through standard forming processes, accommodating other battery components in the recessed second portion while maintaining manufacturing feasibility and avoiding excessive complexity.
Data Source
AI summary
A battery cell includes a packaging bag, a first electrode plate, and a second electrode plate. A second portion of the packaging bag is recessed with respect to a first portion to form a first concave portion on an outer surface of the packaging bag. A second zone of the second electrode plate is recessed with respect to a first zone to form a second concave portion on the second electrode plate. In an extending direction of a first tab, a dimension by which the first zone extends beyond the first electrode plate is denoted as a1, a dimension by which the second zone extends beyond the first electrode plate is denoted as a2, and 0.2 mm≤a1−a2≤4 mm.