Battery Side Seal Folded Edge Design for Volumetric Energy Density
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Solution Overview
Problem
Conventional battery side seal structures occupy excessive space, leading to a decrease in volumetric energy density as batteries become thinner, either by extending in the thickness direction or width direction, thereby reducing their energy storage efficiency.
Innovation Solution
A battery design featuring a side seal with a first folded edge extending along one side face and a second folded edge along the other side face, where the second folded edge is connected to the body and filled with a binder, reducing the overall space occupied by the side seal, thereby enhancing volumetric energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the side seal is bent to form vertical double-folded or single-folded edges, then the side seal can be contained within the battery thickness, but the folded edge length exceeds the battery thickness and occupies space in the thickness direction
Solution Approach 1:
The side seal transitions from a planar structure to a three-dimensional folded structure by bending along specific fold lines. The first folded edge creates vertical folds that contain the side seal within the battery thickness direction, while the second folded edge extends along the lateral face to provide structural support. This dimensional transformation allows the side seal to occupy minimal space in the thickness direction while maintaining structural integrity through the extended lateral folding.
Solution Approach 2:
The side seal is folded back onto itself in a nested configuration where the folded portions are contained within the battery envelope. The first folded edge folds the side seal vertically into the battery thickness, and the second folded edge further nests the structure along the lateral face, creating a compact nested arrangement that minimizes space occupation while preserving the side seal's structural function.
2Volume of moving object
If the side seal extends in the width direction without bending, then the side seal maintains structural simplicity, but it occupies space in the width direction of the battery core
Solution Approach 1:
Instead of extending the side seal in the width direction (horizontal dimension), the invention transforms the side seal structure to fold vertically along the thickness direction through the first folded edge and along the lateral face through the second folded edge. This dimensional redirection moves the side seal from occupying width space to occupying minimal thickness space, achieving compactness without excessive structural complexity.
Solution Approach 2:
The side seal is designed as a flexible thin-walled structure that can be folded along predetermined fold lines. This flexibility allows the side seal to be configured in a compact folded arrangement rather than extending rigidly in the width direction. The thin-walled construction enables the folds to be formed while maintaining the side seal's structural integrity and sealing function.
3Length of moving object
If the battery becomes thinner, then the battery meets light and thin terminal product requirements, but the folded edge length exceeds the battery thickness reducing volumetric energy density
Solution Approach 1:
The side seal structure is redirected from extending in the width direction to folding in the thickness direction through the first folded edge and along the lateral face through the second folded edge. This dimensional reorientation allows the side seal to be contained within the reduced battery thickness without protruding, enabling thinner battery design while maintaining adequate volumetric energy density by minimizing the space occupied by non-active components.
Solution Approach 2:
The side seal is folded back onto itself in a nested configuration that contains the entire side seal structure within the battery envelope. The nested folding arrangement ensures that no portion of the side seal extends beyond the battery thickness, allowing the battery to be made thinner while the side seal remains fully contained, thus preserving volumetric energy density.
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 reduced size of the side seal in both thickness and width directions minimizes space occupation, thereby improving the battery's volumetric energy density without compromising structural integrity or increasing the risk of corrosion.
Implementation Method 1
a binder is filled between the second folded edge and the body
Data Source
Figure 1~2
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Figure 5~6
AI summary
A battery (1, 1a, 1b, 1c, 1d, 1e) includes a battery core (200) and a packaging shell (100). The battery core (200) includes a first side face (201) and a second side face (203) that intersect, and the packaging shell (100) includes a body (10) enclosing the battery core (200) and a side seal (20, 20a, 20b, 20c, 20d, 20e) located on a side of the first side face (203). The side seal (20, 20a, 20b, 20c, 20d, 20e) includes: a first folded edge (21,21e) including a first portion (211) and a second portion (213), wherein the first portion (211) extends along the second side face (203) in a first direction away from the body. The second portion (213) extends from the second end (2113) in a second direction toward the body (10), and a second folded edge (23, 23a, 23b, 23c, 23d, 23e) extending from the fourth end (2133) along the first side face (203).