Deep Format Pouch Cell Housing via Folding and Welding
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Solution Overview
Problem
Conventional pouch cells with drawn cell housings are limited in depth due to material properties, restricting the aspect ratio and energy output, as they rely on a drawing process that limits the thickness to about 10-20 mm, which restricts the amount of active material that can be stored.
Innovation Solution
A pouch cell housing formed via folding and welding of metal laminated film blanks, allowing for a 'deep' pouch cell with a greater aspect ratio and increased energy output by eliminating the drawing process, enabling depths greater than 20 mm without material elongation limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a drawing process is used to form the pouch cell housing, then the manufacturing process is simple and straightforward, but the depth of the pouch cell is limited to about 10-20 mm due to material elongation properties
Solution Approach 1:
The pouch cell housing is divided into multiple planar panels that are joined together to form the three-dimensional structure. This segmentation allows each panel to be formed using simple drawing processes while the overall depth is achieved through the assembly of multiple segments, resolving the contradiction between manufacturing simplicity and depth limitation.
Solution Approach 2:
The invention uses a multi-panel construction where panels are nested and joined together to create the deep pouch structure. Each panel can be independently formed within the drawing depth limitation, but their combination creates the desired deep profile, effectively bypassing the material elongation constraint.
2Quantity of substance
If the pouch cell depth is increased to store more active material, then the energy output increases, but the aspect ratio becomes unbalanced and the drawing process cannot achieve the required depth
Solution Approach 1:
Instead of increasing depth in a single dimension through drawing, the invention uses multiple panels arranged in a three-dimensional configuration. This allows the pouch cell to achieve greater depth by utilizing multiple dimensions and spatial arrangement, maintaining proper aspect ratios while increasing active material capacity.
3Quantity of substance
If the aspect ratio of cell height to length or width is increased to create a deep pouch cell, then more active material can be stored, but the drawing process cannot accommodate such proportions
Solution Approach 1:
The pouch cell housing is segmented into multiple panels that can be independently sized and shaped. This segmentation provides flexibility in achieving various aspect ratios and depth configurations, allowing the design to adapt to different active material storage requirements without being constrained by the limitations of a single drawing process.
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 method allows for the formation of pouch cells with a higher aspect ratio and increased energy storage capacity, as it is free from the depth limitations of conventional drawing processes, enabling deeper profiles and more efficient energy storage without material elongation constraints.
Implementation Method 1
the pouch cell housing is formed via a series of folding and welding steps
Data Source
AI summary
A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.