Foldable Pouch Battery Cell Layout for Compact Pack Integration
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Solution Overview
Problem
Conventional pouch battery cells are limited in their ability to be folded or bent due to sensitive components being located close to the layered body, which restricts compact packaging and energy density.
Innovation Solution
The design incorporates electrode extension areas and lengthened electrode tabs to allow for folding or bending of the pouch battery cell by 90 to 180 degrees, moving sensitive components further away from the layered body and enabling a more compact configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sensitive components are located close to the layered body in conventional pouch battery cells, then the structural integrity is maintained, but the ability to fold or bend is restricted
Solution Approach 1:
The patent extracts sensitive components (tab terminals, welding areas, connection points) from their traditional locations adjacent to the layered body and relocates them to extended electrode tabs that protrude from the pouch. This separation allows the pouch to be folded or bent without compromising the integrity of sensitive components, directly resolving the contradiction between foldability and structural integrity.
Solution Approach 2:
The patent extends electrode tabs outward from the pouch surface in a third dimension, moving sensitive components away from the folding plane. This dimensional relocation allows the pouch body to be folded or bent while keeping sensitive components in a protected position, enabling both foldability and maintained structural integrity.
2Volume of moving object
If the pouch battery cell is folded to provide compact packaging, then the packaging efficiency is improved, but the distance requirements for sensitive components increase
Solution Approach 1:
The patent utilizes the flexibility of the pouch structure to fold or bend the battery cell into compact configurations. The pouch acts as a flexible container that can be deformed into smaller volume arrangements while the extended electrode tabs maintain the necessary distances for sensitive components through their protruding geometry.
Solution Approach 2:
By relocating sensitive components to extended tabs that protrude from the pouch surface, the patent creates spatial separation in three dimensions. This allows the pouch to be folded into compact forms while the extended tabs maintain adequate distances from the layered body, resolving the contradiction between reduced packaging volume and increased component distances.
3Adaptability or versatility
If electrode tabs are lengthened to enable folding, then the foldability is improved, but the device complexity increases
Solution Approach 1:
The extended electrode tabs serve multiple functions: they maintain electrical connectivity, provide structural support for folding, and position sensitive components away from the folded areas. This multi-functionality allows a single structural modification to address multiple requirements, reducing the need for additional complex components and mechanisms.
Data Source
AI summary
Foldable pouch battery cells are provided for use within traction battery packs. An exemplary pouch battery cell may include flexible portions that can be folded to provide a more compact packaging design compared to conventional pouch style battery cells. The proposed designs move sensitive components of the pouch cell further away from a layered body of an electrode assembly of the pouch cell. The flexible portions of the pouch cell are capable of being bent by 90 degrees or more. The compact design facilities increased energy density compared to conventional pouch battery cell designs.