Battery Pouch Exterior Structure for Deep Cell Assembly Mounting
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Solution Overview
Problem
The existing pouch exterior materials for secondary batteries face challenges in forming accommodating portions without breaking, ensuring proper electrode assembly mounting, minimizing atmospheric contact, and increasing energy density, as they often require unnecessary spaces that reduce cell capacity and mechanical strength.
Innovation Solution
A sheet-type pouch exterior material with an inserting portion at the center, symmetrically deepening accommodating portions on either side, and triangular stepped portions at the ends, allowing for easy electrode assembly mounting and thermal fusion without protruding portions, thereby enhancing mechanical strength and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the accommodating portion is formed by compressing the aluminum laminate sheet using a die and punch, then the accommodating portion can be formed to mount the electrode assembly, but the aluminum laminate sheet may break during compression and it is difficult to form the accommodating portion having a depth equal to or greater than 15 mm
Solution Approach 1:
The accommodating portion is divided into a first accommodating portion and a second accommodating portion formed in different aluminum laminate sheets. These segmented portions are then overlapped and sealed together, allowing each portion to be formed with moderate depth without excessive compression force that would cause breaking, while achieving a total depth of at least 15 mm through the combination of both portions.
2Ease of manufacture
If two units of aluminum laminate sheet are combined by being overlapped and sealed to form a separable pouch exterior material, then the electrode assembly can be mounted, but a separate guiding device is required to ensure proper positioning, thereby increasing manufacturing costs
Solution Approach 1:
The first and second accommodating portions are designed with self-aligning features where the electrode assembly itself guides the positioning during the overlapping and sealing process. The structure allows the accommodating portions to automatically align with the electrode assembly edges without requiring external guiding devices, simplifying the manufacturing process while ensuring proper positioning.
3Ease of manufacture
If two units of aluminum laminate sheet are combined on four sides to form sealing portions, then the pouch exterior material can be assembled, but the two units are in contact with the atmosphere from all four sides, thereby increasing the possibility of air inflow and reducing battery life
Solution Approach 1:
One side of the pouch exterior material is left open without sealing, extracting the sealing process from all four sides to only three sides. This open side allows the electrode assembly to be inserted and positioned before sealing, while the three sealed sides provide sufficient protection against atmospheric contact. This reduces air inflow risk compared to fully sealed structures while maintaining ease of assembly.
4Ease of manufacture
If the accommodating portions are overlapped and three sides are sealed, then manufacturing is simplified, but unnecessary spaces remain that reduce energy density of the cell
Solution Approach 1:
The depths of the first and second accommodating portions are optimized to match the electrode assembly dimensions precisely. By adjusting the depth parameters and overlapping configuration, unnecessary spaces are eliminated while maintaining the three-side sealing structure. This ensures maximum utilization of the pouch interior volume for active materials, increasing energy density without complicating the sealing process.
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
This design prevents material breakage during assembly, reduces atmospheric contact, and increases energy density by eliminating unnecessary spaces, improving cell capacity and cooling performance while simplifying assembly and module integration.
Implementation Method 1
thermally fusing a separate aluminum laminate sheet separated from the aluminum laminate sheet or the aluminum laminate sheet that is extended while the electrode assembly is provided in the accommodating portion
Data Source
AI summary
A pouch exterior material that enables an electrode assembly to be easily mounted on an accommodating portion at a proper position, having an integrated shape and including an inserting portion provided at a center of the pouch exterior material and having a width equal to a thickness of the electrode assembly, accommodating portions provided symmetrically at two sides of the inserting portion and gradually deepening from a portion corresponding to a width center of the electrode assembly towards a portion corresponding to an edge of the electrode assembly, and a triangular stepped portion provided at two ends of the inserting portion and having a depth gradually decreasing towards an end.