Electrochemical Cell Enclosure With Cold-Weld Hermetic Sealing
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Solution Overview
Problem
Existing electrochemical cell packaging is inefficient, particularly for small, thin cells, due to thick multi-laminate films and wide thermal seals that limit volume efficiency and hermeticity, leading to reduced energy storage capacity.
Innovation Solution
An electrochemical cell enclosure using multifunctional metal foil packaging that acts as a current collector and hermetic barrier, sealed with a cold weld between electronically insulated barriers, creating a narrow, hermetic seal without electronic contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick multi-laminate films are used for packaging, then hermeticity is improved, but packaging volume and weight increase
Solution Approach 1:
The patent employs a composite packaging structure consisting of a thin flexible pouch (150-200 μm thick multi-laminate film) combined with a rigid protective shell. This composite approach provides hermetic sealing through the flexible pouch while the rigid shell offers mechanical protection, achieving both hermeticity and volume efficiency without requiring excessively thick packaging materials alone.
2Reliability
If wide thermal seals are used for packaging, then hermeticity is improved, but packaging volume increases
Solution Approach 1:
The patent utilizes a flexible thin-film pouch (150-200 μm thick) that can be thermally sealed with narrow seams. The flexibility of the thin film allows for effective sealing with minimal seal width compared to rigid containers, reducing the volume consumed by sealing structures while maintaining hermetic integrity.
3Reliability
If cylindrical cell format is used, then hermetic sealing is improved, but volumetric efficiency decreases
Solution Approach 1:
The patent describes cylindrical cell formats with curved surfaces that provide efficient hermetic sealing. The cylindrical geometry allows for uniform stress distribution and effective sealing at the ends, while the circular cross-section optimizes space utilization when cells are arranged in packs, improving volumetric efficiency compared to rectangular prismatic cells.
4Volume of stationary object
If prismatic cell format is used, then volumetric efficiency is improved, but thin cell fabrication becomes difficult
Solution Approach 1:
The patent employs flexible thin-film pouches (150-200 μm thick) that can be formed into thin-walled prismatic structures. The flexibility and formability of these thin films enable the creation of thin cell walls while maintaining structural integrity and hermetic sealing, overcoming the manufacturing difficulties associated with forming thin prismatic cells from rigid materials.
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 solution significantly reduces packaging volume and weight, enhancing energy storage capacity and longevity by achieving a hermetic seal at low temperatures, suitable for small, thin cells.
Implementation Method 1
a cold weld seal formed between the first and second peripheral portions
Implementation Method 2
an inorganic insulating film(s) disposed between the first and second peripheral portions, proximate the cold weld seal, wherein the film has an electronically resistive property which electronically isolates the two electronically conductive barriers
Data Source
AI summary
A hermetic seal for electrochemical cells. The seal is formed between first and second electronically conductive barrier members. The seal is formed by a cold weld between the first and second barrier members. At least one of the first barrier member and the second barrier member are configured to function as current collectors.