Folded Pouch Cell Case Structure Without Foaming Limits
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Solution Overview
Problem
Conventional pouch type secondary battery manufacturing processes are limited by mechanical and physical properties of materials, leading to defects like warpage and limited shape and size, and high material costs due to the need for foaming processes.
Innovation Solution
A pouch type secondary battery design that forms a space for housing the electrode assembly by folding space-forming sections in parallel, with tab drawing sections extending perpendicularly, and using sealing parts to create a pouch case without a foaming process, allowing for a thicker cell structure and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a foaming process is used to form the pouch case, then the pouch case can be formed with appropriate mechanical properties, but the material costs increase and the thickness of the cell is limited
Solution Approach 1:
The invention extracts and eliminates the foaming process from the pouch case manufacturing. The pouch case is formed directly from a foil through folding and sealing operations, removing the need for foaming agents and associated materials, thereby reducing material costs while maintaining structural integrity
Solution Approach 2:
The invention replaces the chemical foaming process with a mechanical folding and sealing system. The pouch case structure is created through physical manipulation of the foil (folding along imaginary lines and sealing edges) rather than through chemical expansion, substituting a mechanical formation process for a chemical one
2Strength
If a foaming process is used to form the pouch case, then the pouch case can be formed, but the thickness of the cell is limited by mechanical and physical properties of the material
Solution Approach 1:
The invention segments the pouch case formation into discrete folding operations along imaginary lines. By dividing the foil into multiple foldable sections, the structure can accommodate greater thickness variations without compromising structural integrity, as each segment can be independently formed and sealed
Solution Approach 2:
The invention changes the formation parameters of the pouch case from a chemical foaming process with fixed thickness constraints to a mechanical folding process with variable thickness capabilities. This allows the cell thickness to be adjusted based on the electrode assembly requirements without being constrained by material foaming properties
3Ease of manufacture
If the pouch case is formed by conventional pressing, then the pouch can be manufactured, but defects such as warpage phenomenon occur
Solution Approach 1:
The invention performs preliminary folding actions along imaginary lines before final sealing. This pre-positioning of folds ensures that the pouch case maintains its intended shape throughout the manufacturing process, preventing warpage by establishing the correct geometry early in the formation sequence
Solution Approach 2:
The invention introduces dynamic, sequential folding and sealing operations rather than a static pressing process. The pouch case is formed through a series of controlled movements and folds that adapt to the material properties, allowing the structure to self-adjust and maintain precision without the warpage issues associated with conventional pressing
Data Source
AI summary
The present invention provide a pouch type secondary battery and a method for manufacturing the same. More particularly, the present invention provides a pouch type secondary battery and a method for manufacturing the same, in which a pouch case is formed in a folding manner without being subjected to a forming process (press process), such that there is no limit in a length, and a thickness of an inner space of the pouch case is not limited.