Pouch Cell Electrode Flange Structure for Rigid External Connection

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Solution Overview

Problem

Pouch cells face challenges in maintaining rigidity at the electrode lead, leading to unreliable connections when connected to external devices, which can result in bending or breaking, compromising the mechanical security and safety performance.

Innovation Solution

The electrochemical apparatus incorporates a housing with integrally formed flange and inserting portions for the electrodes, which snap-fit into the housing, increasing contact area and grip force, thereby enhancing the rigidity and safety by eliminating the need for welding and reducing internal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the electrode lead is made flexible for pouch cell construction, then the cell can be easily assembled, but the rigidity at the electrode lead is insufficient leading to unreliable connections

Engineering Contradiction:

Improveease of assemblyVSAvoidrigidity of electrode lead

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The electrode lead is divided into two distinct parts: a flexible electrode portion for connection to the pouch cell and a rigid inserting portion for connection to the external device. This segmentation allows each part to have optimized properties - the electrode portion remains flexible for easy assembly while the inserting portion provides rigidity for reliable mechanical support and connection.

Inventive Principle:

Principle #1Segmentation

2Reliability

If welding is used to connect the electrode to the housing, then electrical connection is achieved, but the welding point generates heat causing electrolyte instability and side reactions

Engineering Contradiction:

Improveelectrical connectionVSAvoidheat generation and side reactions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The welding process (thermal connection method) is replaced with a mechanical snap-fit connection system. The inserting portion is mechanically engaged with the housing through snap-fit structures, eliminating the need for welding. This substitution removes the heat generation issue entirely while maintaining reliable electrical connection through the mechanical interface.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Weight of moving object

If the electrode lead is made thinner to reduce weight, then the cell weight decreases, but the electrode cannot support the weight of the cell

Engineering Contradiction:

Improvecell weightVSAvoidsupport capacity of electrode

Core Design Contradiction:

Weight of moving objectVSForce

Solution Approach 1:

The electrode lead is segmented into a thin flexible electrode portion for weight reduction and a thick rigid inserting portion for mechanical support. The thin electrode portion minimizes weight while the thick inserting portion provides sufficient structural strength to support the cell weight, with each segment optimized for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrode lead structure functions as a composite system combining materials with different properties - the electrode portion uses conductive material optimized for electrical performance and flexibility, while the inserting portion uses structurally superior material optimized for mechanical strength and rigidity, achieving both weight reduction and support capacity.

Inventive Principle:

Principle #40Composite materials

4Reliability

If welding is used to connect electrode components, then electrical connection is established, but the manufacturing process becomes more complex and time-consuming

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The complex welding process is replaced with a simple mechanical snap-fit assembly process. The inserting portion with integrated snap-fit structures can be directly assembled into the housing without any thermal processing, significantly simplifying the manufacturing process while maintaining reliable electrical connection through the mechanical interface.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connecting function and supporting function are merged into a single integrated inserting portion structure. This single component simultaneously provides electrical connection, mechanical support, and structural integration with the housing, eliminating the need for separate welding operations and reducing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20230291046A1Electrochemical apparatus and electronic device

Publication Date: 2023.09.14 NINGDE AMPEREX TECHNOLOGY LTD

AI summary

An electrochemical apparatus and an electronic device, the electrochemical apparatus including a housing, an electrode assembly, and a first electrode. The housing includes a first part and a second part that are interconnected, where the electrode assembly is accommodated in an accommodating cavity of the first part. The first electrode includes a first inserting portion and a first flange portion, where the first flange portion and the first inserting portion are integrally formed, the first flange portion embeddedly snap-fits into the second part, the first flange portion is connected to the electrode assembly, and the first inserting portion extends away from the accommodating cavity and protrudes from an outer surface of the second part.