Battery Formation Charging Profile for Swelling Reduction

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Solution Overview

Problem

Battery swelling during the initial cycles of the manufacturing process, which can lead to aesthetic and functional damage, is not adequately addressed by existing technologies.

Innovation Solution

Adjusting manufacturing parameters such as extending the charging time, varying the charge rate based on voltage range, and altering the temperature based on cutoff voltage during the formation stage to saturate the solid electrolyte interface (SEI), thereby reducing swelling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the battery undergoes initial charging and discharging cycles during the formation stage, then the solid electrolyte interface (SEI) is formed, but battery swelling occurs leading to aesthetic and functional damage

Engineering Contradiction:

Improvebattery longevityVSAvoidbattery swelling

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by extending the charging time at high voltage levels during the formation stage before the battery enters normal operation. This preliminary extended charging saturates the SEI formation process, preventing subsequent swelling during the battery's service life. The additional charging time in the formation stage proactively addresses the swelling issue before it affects battery reliability.

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If the charging time at high voltage level is extended during the formation process, then battery swelling is reduced, but the manufacturing time increases

Engineering Contradiction:

Improvebattery swellingVSAvoidformation process duration

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The patent applies dynamics by implementing a voltage-range-dependent charging strategy where the charge rate varies dynamically based on the battery's voltage level. The method charges at higher rates during mid-voltage ranges and reduces rates near full charge, optimizing the balance between SEI saturation and manufacturing time. This dynamic approach prevents swelling while minimizing unnecessary time extension compared to uniformly slow charging.

Inventive Principle:

Principle #15Dynamics

3Productivity

If the charge rate is increased to reduce manufacturing time, then productivity improves, but the SEI saturation is insufficient leading to battery swelling

Engineering Contradiction:

Improveformation process efficiencyVSAvoidswelling prevention

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies parameter changes by systematically varying charging parameters (current, voltage, temperature) based on the battery's state during formation. Specifically, it adjusts the charge rate and temperature based on voltage ranges to ensure adequate SEI saturation while maintaining reasonable manufacturing time. This parameter optimization resolves the contradiction between productivity and swelling prevention.

Inventive Principle:

Principle #35Parameter changes

4Loss of time

If the temperature is increased during charging to accelerate SEI formation, then the formation process is faster, but excessive swelling may occur due to uncontrolled reactions

Engineering Contradiction:

Improveformation process durationVSAvoidbattery swelling

Core Design Contradiction:

Loss of timeVSObject-affected harmful factors

Solution Approach 1:

The patent applies periodic action by implementing temperature variations during the charging process rather than maintaining a constant high temperature. The temperature is adjusted in periods or stages corresponding to different voltage ranges and charging phases, allowing SEI formation to proceed efficiently while preventing thermal runaway and excessive swelling. This periodic temperature control balances speed and safety.

Inventive Principle:

Principle #19Periodic action

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 proposed method effectively prevents battery swelling by enhancing the formation process, leading to improved battery longevity and reduced risk of damage.

Implementation Method 1

a duration of the charging at a high voltage level is maintained for an extended time period, thereby saturating a solid electrolyte interface (SEI) during the formation process and reducing a swelling of the battery

Methodology Applied

Scientific EffectSolid electrolyte interface (SEI) saturation:

Data Source

PatentUS20250309318A1Battery manufacturing process to reduce swelling

Publication Date: 2025.10.02 LENOVO (SINGAPORE) PTE LTD

AI summary

A battery is charged and discharged during a battery manufacturing formation process according to a current and voltage profile. The duration of the charging at a high voltage level is maintained for an extended time period, thereby saturating a solid electrolyte interface (SEI) during the formation process and reducing a swelling of the battery.