Battery Cell End Cover Recess for Higher Capacity Packaging

Solution Overview

Problem

The capacity of conventional lithium-ion batteries is limited by the structure of the battery cell, particularly due to the protruding length of the electrode terminal which occupies excessive space.

Innovation Solution

The end cover of the battery cell incorporates a first convex portion with a recessed first concave portion to accommodate the electrode terminal, reducing its protrusion and optimizing space utilization within the battery cell.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electrode terminal is made longer for electrical connection, then the electrical connection reliability is improved, but the space occupied by the terminal protruding from the battery cell increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidspace occupied by electrode terminal

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The electrode terminal is nested within the concave portion of the end cover assembly. The terminal is received and housed inside the recessed cavity formed by the concave portion, allowing the terminal to be contained within the overall envelope of the battery cell rather than protruding externally. This nesting arrangement maintains the terminal's functional length for electrical connection while eliminating the volume penalty of external protrusion.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The design transitions the terminal accommodation from a one-dimensional external protrusion to a three-dimensional internal cavity utilization. By creating a concave portion that extends into the end cover assembly, the terminal is positioned in an additional spatial dimension (inside the end cover rather than outside), effectively reducing the external footprint while maintaining internal length for electrical function.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If the electrode terminal protrudes longer from the battery cell, then the electrical connection is easier to make, but the battery capacity is reduced due to less space for electrode assembly

Engineering Contradiction:

Improveease of electrical connectionVSAvoidbattery capacity

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The electrode terminal is nested within the concave portion of the end cover assembly. The terminal is received and housed inside the recessed cavity formed by the concave portion, allowing the terminal to be contained within the overall envelope of the battery cell rather than protruding externally. This nesting arrangement maintains the terminal's functional length for electrical connection while eliminating the volume penalty of external protrusion.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The design transitions the terminal accommodation from a one-dimensional external protrusion to a three-dimensional internal cavity utilization. By creating a concave portion that extends into the end cover assembly, the terminal is positioned in an additional spatial dimension (inside the end cover rather than outside), effectively reducing the external footprint while maintaining internal length for electrical function.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Quantity of substance

If more battery cells are packed in a given volume, then the overall battery capacity increases, but each individual cell must have reduced dimensions

Engineering Contradiction:

Improveoverall battery capacityVSAvoidindividual cell volume

Core Design Contradiction:

Quantity of substanceVSVolume of moving object

Solution Approach 1:

The electrode terminal is nested within the concave portion of the end cover assembly. The terminal is received and housed inside the recessed cavity formed by the concave portion, allowing the terminal to be contained within the overall envelope of the battery cell rather than protruding externally. This nesting arrangement maintains the terminal's functional length for electrical connection while eliminating the volume penalty of external protrusion.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The design transitions the terminal accommodation from a one-dimensional external protrusion to a three-dimensional internal cavity utilization. By creating a concave portion that extends into the end cover assembly, the terminal is positioned in an additional spatial dimension (inside the end cover rather than outside), effectively reducing the external footprint while maintaining internal length for electrical function.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12388143B2Battery cell, battery, power consumption device and manufacturing device and method for battery cell

Publication Date: 2025.08.12 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

An embodiment of the present application provides a battery cell, a battery, a power consumption device, and a manufacturing equipment and method for a battery cell. The battery cell includes a housing, an electrode assembly, an end cover to cover the housing, and an electrode terminal installed on the end cover and electrically connected with the electrode assembly. The end cover includes a first body and a first convex portion, and the first convex portion extends from the first inner surface of the first body along a direction facing the electrode assembly, a position on the first body corresponding to the first convex portion is formed with a first concave portion recessed from the first outer surface opposite to the first inner surface along the direction facing the electrode assembly, the first concave portion is configured to accommodate the electrode terminal. The battery cell can effectively increase the battery capacity.