Battery Housing Structure for Uniform Cell Compression

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Solution Overview

Problem

Batteries experience performance issues due to heat generation and uneven expansion/contraction of electrochemical cells during charging and discharging, leading to problems like dendrite formation and uneven pressure distribution.

Innovation Solution

Applying high-magnitude, uniform anisotropic forces to electrochemical cells using thermally conductive and insulating components, along with alignment features to maintain uniform pressure distribution and manage thermal transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If electrochemical cells undergo high expansion and contraction during charging and discharging, then battery capacity and energy density improve, but battery housing expansion and structural stability deteriorate

Engineering Contradiction:

Improvebattery capacityVSAvoidhousing structural stability

Core Design Contradiction:

Use of energy by moving objectVSStability of the object's composition

Solution Approach 1:

The battery housing is divided into a rigid housing portion and a compliant housing portion. The rigid portion maintains overall structural stability and shape, while the compliant portion locally absorbs expansion and contraction forces from electrochemical cells during charging and discharging cycles, preventing stress concentration and structural failure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the housing are assigned different mechanical properties: the rigid housing portion provides structural support and maintains battery shape, while the compliant housing portion specifically at cell contact regions accommodates dimensional changes of electrochemical cells, optimizing both structural integrity and cell expansion accommodation.

Inventive Principle:

Principle #3Local quality

2Power

If high magnitudes of force are applied to electrochemical cells to improve performance, then current density and electrochemical reaction efficiency improve, but uneven pressure distribution and dendrite formation worsen

Engineering Contradiction:

Improvecurrent densityVSAvoiddendrite formation resistance

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The housing is designed to apply uniform pressure distribution across all electrochemical cells through its rigid structure and compliant interface. This equipotential pressure distribution ensures that high magnitudes of force improve current density uniformly without creating localized high-stress regions that would promote dendrite formation and uneven electrochemical reactions.

Inventive Principle:

Principle #12Equipotentiality

3Stability of the object's composition

If battery housing is designed to accommodate cell expansion, then cell dimensional changes are tolerated, but battery volume and pack burden increase

Engineering Contradiction:

Improvecell expansion accommodationVSAvoidbattery volume

Core Design Contradiction:

Stability of the object's compositionVSVolume of moving object

Solution Approach 1:

The housing structure integrates multiple functions: the rigid portion provides structural support and defines battery volume, while the compliant portion simultaneously accommodates cell expansion and maintains compact battery geometry. This merging of structural and compliant functions allows the battery to tolerate cell dimensional changes without significant volume increase or pack burden.

Inventive Principle:

Principle #5Merging (Combining)

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

Improves battery performance by reducing dendrite formation, enhancing current density, and maintaining uniform pressure distribution while achieving high energy density and durability.

Implementation Method 1

the housing is configured to apply, during at least one period of time during charge and/or discharge of the first electrochemical cell and/or the second electrochemical cell, an anisotropic force with a component normal to the first electrode active surface and the second electrode active surface defining a pressure of at least 10 kgf/cm2

Methodology Applied

Scientific EffectAnisotropic force application: Mechanical Force

Implementation Method 2

thermally conductive solid articles that can be used for aligning components of the battery

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

thermally insulating and compressible components for battery packs

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250279558A1Batteries, and associated systems and methods

Publication Date: 2025.09.04 SION POWER CORP

AI summary

Batteries including electrochemical cells, associated components, and arrangements thereof are generally described. In some aspects, batteries with housings that undergo relatively little expansion and contraction even in cases where electrochemical cells in the battery undergo a relatively high degree of expansion and contraction during charging and discharging are provided. Batteries configured to apply relatively high magnitudes and uniform force to electrochemical cells in the battery, while in some cases having high energy densities and a relatively low pack burden, are also provided. In certain aspects, arrangements of electrochemical cells and associated components are generally described. In some aspects, thermally conductive solid articles that can be used for aligning components of the battery are described. In some aspects, thermally insulating and compressible components for battery packs are generally described.