Lithium-Ion Battery Stack Encapsulation for Low-Resistance Connections
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Solution Overview
Problem
Existing battery manufacturing methods face issues such as leakage currents, material loss, high resistance, and unsatisfactory encapsulation, leading to reduced performance and increased costs in high-power lithium-ion batteries.
Innovation Solution
A novel battery architecture with through-holes and conductive means in alternating anode and cathode foils, combined with a multi-layer encapsulation system, reduces resistance and enhances electrical connections while minimizing material loss and encapsulation weaknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If alternating anode and cathode foils are superimposed with lateral offsetting to form a stack, then production output and energy density are improved, but leakage currents and short-circuit risks occur at the edges
Solution Approach 1:
An encapsulation system is introduced as an intermediary element between the laterally offset anode and cathode foils. This encapsulation layer fills the gaps created by the offset configuration and provides electrical insulation, preventing leakage currents while maintaining the high-density stacked structure. The encapsulation system acts as a mediator that enables the beneficial offset arrangement without suffering from its harmful edge effects.
2Productivity
If the stack is cut along cutting planes to obtain unit batteries, then individual battery production is achieved, but the encapsulation system is torn off and the impervious seal is broken
Solution Approach 1:
The encapsulation system is applied to the entire stacked structure before the cutting operation. This preliminary encapsulation creates a robust protective layer that remains intact during subsequent cutting processes. The encapsulation is deposited conformally over the offset foils, ensuring that even when cuts are made to separate unit batteries, the encapsulation maintains the impervious seal and prevents damage to the internal structure.
3Strength
If a conformal thick-layer encapsulation system is deposited on the stack, then structural stiffness and atmospheric protection are improved, but material loss increases and deposition on offset edges is unsatisfactory
Solution Approach 1:
The encapsulation system parameters are optimized to achieve the desired stiffness and protection with minimal material usage. By controlling the deposition thickness and composition, the encapsulation provides sufficient mechanical reinforcement and atmospheric barrier properties while reducing excess material consumption. The conformal deposition ensures uniform coverage even in the offset regions, eliminating wasted material from uneven or excessive application.
4Ease of operation
If cathode and anode connections are exposed on cutting planes, then electrical terminations can be added, but contact resistance increases and connection reliability deteriorates
Solution Approach 1:
Instead of exposing connections only on the cutting planes (two-dimensional surface exposure), the encapsulation system is designed to maintain connection accessibility through three-dimensional structuring. The offset configuration and encapsulation approach allow terminations to be accessed from multiple dimensions, reducing contact resistance by providing better electrical pathways while maintaining connection reliability through protected exposure points.
Data Source
AI summary
High-power battery architecture comprising unique anode and cathode conductive means procuring improved battery life.