Battery Pouch with Metallic Base Plate for High Capacity
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Solution Overview
Problem
The existing pouch structures for lithium secondary batteries face challenges in accommodating high-capacity batteries with a large number of stacks, as they tend to increase in thickness, limiting the battery thickness to 5 mm or less due to forming limitations, which restricts the number of parallel connections needed for cost reduction and capacity enhancement.
Innovation Solution
A pouch configuration featuring an upper housing module with a metallic base plate and a polymer reinforcing layer, combined with a lower pouch sheet, allowing for a more flexible and reinforced structure that can accommodate high-capacity batteries with multiple stacks, using materials like aluminum, cast polypropylene, and alloys for enhanced strength and sealability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of stacks in the battery is increased to enhance capacity, then the battery capacity increases, but the battery thickness increases significantly
Solution Approach 1:
The pouch is divided into an upper housing module with a metallic base plate and a lower pouch sheet, creating a segmented structure that allows independent optimization of each section. This segmentation enables the battery to accommodate more stacks without uniformly increasing overall thickness.
Solution Approach 2:
The invention transitions from a conventional single-layer pouch structure to a three-dimensional composite structure with a metallic base plate providing structural support in the thickness direction, allowing capacity enhancement through additional stacks without proportional thickness increase.
2Strength
If the pouch structure is reinforced to accommodate more stacks, then the structural strength increases, but the manufacturing complexity increases
Solution Approach 1:
The pouch combines a metallic base plate (aluminum or alloy) with polymer pouch sheets to create a composite structure. This composite material approach provides enhanced structural strength and stiffness while maintaining manufacturability through established metal-forming and pouch-welding technologies.
Solution Approach 2:
The metallic base plate is strategically positioned at the bottom of the pouch where structural support is most needed to bear the weight and pressure of multiple battery stacks. This localized reinforcement provides strength where required without unnecessarily complicating the entire pouch structure.
3Length of moving object
If the pouch thickness is reduced to maintain compact form factor, then the form factor is improved, but the number of parallel connections is reduced
Solution Approach 1:
The upper portion of the pouch uses flexible polymer sheets that can be closely fitted to the battery stacks, maximizing space utilization in the thickness direction. This flexible film structure allows accommodation of multiple parallel connections without increasing overall pouch thickness.
Solution Approach 2:
By introducing the metallic base plate as a rigid support structure, the invention creates vertical space efficiency, allowing horizontal arrangement of multiple parallel connections within a constrained thickness envelope that would not be possible with conventional flexible pouches alone.
4Ease of manufacture
If conventional pouch materials are used to maintain simplicity, then the manufacturing simplicity is maintained, but the sealability and insulation are insufficient
Solution Approach 1:
The metallic base plate provides superior barrier properties for sealability and electrical insulation compared to conventional single-layer polymer pouches. The composite structure combines the ease of polymer processing with the superior protective properties of metal, achieving enhanced reliability without significantly complicating manufacturing.
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 configuration enables the storage of high-capacity batteries with a large number of stacks without significant thickness increase, improving sealability and insulation while allowing for easier assembly and reduced material costs by simplifying the connection process through integrated lead tabs.
Implementation Method 1
the closely attached portions are thermally welded to form the sealed pouch-type secondary battery
Data Source
AI summary
Provided is a structure of a pouch which may be used in a high-capacity battery having high capacity and high stiffness, wherein the pouch may include an upper housing module which includes a metallic base plate having a concave-shaped accommodation space and polymer layers formed on one surface or both surfaces of the base plate, and a lower pouch sheet which is combined with a lower surface of the upper housing module to seal the accommodation space.