Zigzag Folded Solid-State Cell Assembly for Higher Packing Density
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Solution Overview
Problem
Conventional battery cell assemblies face challenges in maximizing voltage capacity and volumetric efficiency in limited spaces due to overlapping components and increased assembly complexity, which affects the mileage of electric vehicles.
Innovation Solution
A battery cell assembly featuring a folding solid-state unit cell in a zigzag form with terminal plates and a housing structure that allows for efficient electrical connections and reduced parts, enabling increased voltage capacity and simplified assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional battery modules with liquid electrolyte cells are used, then electrical connection capacity is achieved, but volumetric efficiency deteriorates due to overlapping components and increased assembly complexity
Solution Approach 1:
The patent merges multiple separate components (battery cells, cooling plates, terminal plates, and housing) into an integrated cell assembly structure. The first and second battery cells are positioned adjacent to each other with terminal plates and cooling plates integrated into the same assembly, eliminating the need for separate module housings and reducing the number of assembly parts.
Solution Approach 2:
The terminal plates serve multiple functions: electrical connection between cells, structural support, and integration with cooling plates. The housing simultaneously provides mechanical protection, thermal management pathways, and structural framework, reducing the need for dedicated separate components for each function.
2Reliability
If multiple separate components are used for battery assembly, then functional requirements are met, but assembly complexity increases and manufacturing efficiency decreases
Solution Approach 1:
The battery system is segmented into discrete cell assemblies, each containing a specific number of battery cells (first and second cells) with integrated terminal and cooling plates. This segmentation allows for standardized manufacturing of individual assemblies that can be easily handled and assembled, reducing overall assembly complexity while maintaining functional integrity.
Solution Approach 2:
The terminal plates and cooling plates are pre-integrated with the battery cells during cell assembly formation, creating pre-assembled units with electrical connections and thermal management pathways already in place. This preliminary integration simplifies subsequent assembly steps when multiple cell assemblies are combined into the complete battery pack.
Data Source
AI summary
A battery cell assembly includes: a folding cell in which a solid-state unit cell in a sheet form is folded in a zigzag form; a first terminal plate disposed on a first side with reference to a folding direction of the folding cell, electrically connected to the folding cell through at least one first electrode terminal, and formed with at least one protrusion portion configured to support the at least one first electrode terminal; and a second terminal plate disposed on a second side with reference to the folding direction of the folding cell, electrically connected to the folding cell through at least one second electrode terminal, and formed with at least one recess portion configured to support the at least one second electrode terminal.