Multi-Layer Cell Laminate as Casing and Current Collector
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Solution Overview
Problem
The manufacture of electrochemical cells, such as batteries, is complex and capital-intensive, often requiring binding agents that occupy space, impede conductivity, and increase processing complexity, while existing packaging materials are not used as functional components.
Innovation Solution
A multi-layer laminate sheet is used as both the casing and current collector for electrochemical cells, featuring an outer layer, an intermediate conductive layer, and an inner layer with openings for electrical connection, allowing the electrochemically active material to be directly connected to the conductive region, thereby simplifying the manufacturing process and eliminating the need for separate tabbing and sealing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binding agents are used to compress components into a cohesive assembly, then structural integrity is improved, but processing complexity and space occupation increase while conductivity is impeded
Solution Approach 1:
The patent removes the binding agent component entirely from the battery assembly. The pouch structure is designed to function as both packaging and current collector without requiring additional binding materials to hold components together, thereby eliminating the associated processing complexity and space occupation while maintaining structural integrity through the pouch's mechanical design
Solution Approach 2:
The pouch is designed to perform multiple functions simultaneously: it serves as the outer packaging, the current collector, and the structural framework. This multi-functionality eliminates the need for separate binding agents and dedicated tab components, reducing processing steps while maintaining the necessary structural integrity for component assembly
2Reliability
If separate tab components and dedicated sealing operations are used, then electrical connection reliability is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent merges the pouch structure with the current collector function, eliminating the need for separate tab components. The pouch itself serves as the electrical conductor that collects current from the electrodes, thereby reducing the number of discrete parts and sealing operations required while maintaining reliable electrical connection through the integrated design
Solution Approach 2:
The pouch performs dual functions as both packaging and current collector, eliminating the need for dedicated tab components and separate sealing operations. This integration maintains electrical connection reliability while significantly improving manufacturing efficiency by reducing the number of assembly steps
3Object-affected harmful factors
If packaging materials are used separately from functional components, then protection is improved, but space and cost increase
Solution Approach 1:
The pouch is designed to simultaneously serve as the protective packaging and the current collector. By integrating these two functions into a single component, the patent eliminates the need for separate packaging materials, thereby reducing the overall volume and material usage while maintaining both protection and electrical functionality
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 approach reduces packaging complexity, maintains energy storage capabilities, and integrates the casing as a functional component, enhancing manufacturing efficiency and reducing costs by eliminating the need for discrete tab components and dedicated sealing operations.
Implementation Method 1
The inner layer defines an opening through which a conductive region of the intermediate layer is exposed such that the electrode material can be electrically connected to the conductive region and the intermediate layer can serve as a current collector
Data Source
AI summary
Electrochemical cells and methods of making electrochemical cells are described herein. In some embodiments, an apparatus includes a multi-layer sheet for encasing an electrode material for an electrochemical cell. The multi-layer sheet including an outer layer, an intermediate layer that includes a conductive substrate, and an inner layer disposed on a portion of the conductive substrate. The intermediate layer is disposed between the outer layer and the inner layer. The inner layer defines an opening through which a conductive region of the intermediate layer is exposed such that the electrode material can be electrically connected to the conductive region. Thus, the intermediate layer can serve as a current collector for the electrochemical cell.