Battery Cell Swelling Compensation With Selective Cooling Paths

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Solution Overview

Problem

Secondary batteries face issues with electrode swelling/shrinking, electrolyte loss, and thermal management, which affect performance and longevity, particularly during rapid charging and discharging.

Innovation Solution

A battery cell design incorporating a swelling compensation member with a porous structure that shrinks and expands to accommodate electrode swelling/shrinking, providing thermal insulation and electrolyte replenishment, and a cooling member for heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a rigid housing is sized to accommodate electrode swelling, then electrode swelling damage is prevented, but battery capacity and life-span decrease due to reduced pressure on electrode assembly

Engineering Contradiction:

Improvehousing structural integrityVSAvoidbattery capacity and life-span

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent introduces a swelling compensation member with elastic or viscoelastic properties that can dynamically change its volume and shape in response to electrode assembly swelling and shrinking during charge/discharge cycles. This dynamic behavior allows the housing to maintain both structural integrity and optimal pressure on the electrode assembly, resolving the contradiction between preventing swelling damage and maintaining battery performance.

Inventive Principle:

Principle #15Dynamics

2Strength

If a swelling compensation member is added to accommodate electrode swelling, then electrode swelling damage is prevented, but device complexity increases

Engineering Contradiction:

Improvehousing structural integrityVSAvoidbattery cell structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The swelling compensation member is designed to perform multiple functions simultaneously: it accommodates electrode swelling, maintains compression on the electrode assembly, provides thermal insulation, and can serve as an electrolyte reservoir. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving the desired structural protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent specifies that the swelling compensation member should have a porous structure, which allows it to absorb and release electrolyte, providing additional functionality as an electrolyte reservoir while maintaining its mechanical swelling compensation properties. The porous structure enables the material to perform multiple functions with a single component, reducing overall system complexity.

Inventive Principle:

Principle #31Porous materials

3Strength

If the entire inner surface of the housing contacts the swelling compensation member, then electrode swelling is fully accommodated, but thermal insulation prevents heat dissipation from the battery cell

Engineering Contradiction:

Improveelectrode assembly protectionVSAvoidbattery cell temperature

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent applies the swelling compensation member selectively to specific regions of the housing rather than the entire inner surface. This local application allows thermal management components to be positioned in areas where heat dissipation is critical, while still providing swelling compensation and thermal insulation in areas where it is most needed. The swelling compensation member is typically applied to the sides and top of the housing, leaving the bottom surface exposed for thermal management.

Inventive Principle:

Principle #3Local quality

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 design maintains electrode compression, extends battery life by replenishing electrolyte, and prevents thermal runaway by insulating and cooling the battery cell effectively.

Implementation Method 1

Because the swelling compensation member comprises a sponge like material having a porous structure, the swelling compensation member acts as a thermal insulator which is beneficial to help prevent heat transfer from the battery cell to other components, or other battery cells.

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

a cooling member in thermal contact with the outermost surface of the housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12374734B2Battery cell with internal swelling relief and external cooling features

Publication Date: 2025.07.29 DYSON TECH LTD

AI summary

A battery cell including an electrode assembly contained within a housing. The electrode assembly shrinks and/or swells depending on a charge/discharge cycle of the cell. A swelling compensation member configured to shrink upon swelling of the electrode assembly, and expand upon on shrinking of the electrode assembly is in continuous contact with the electrode assembly and an innermost surface of the housing. A first portion of the innermost surface of the housing is in contact with the swelling compensation member, and a second portion is free from contact with the swelling compensation member. The battery cell includes a cooling member in thermal contact with the outermost surface of the housing. Part of the outermost surface of the housing in contact with the cooling member corresponds to a part of the innermost surface of the housing which is free from contact with the swelling compensation member.