Heat-rejecting lead tab for pouch cell cooling

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Solution Overview

Problem

Existing lithium-ion pouch battery cells face challenges in effective heat management during fast charge events, as conventional cooling methods do not adequately address the heat flux paths within the cell assembly, potentially leading to reduced performance and longevity.

Innovation Solution

A modified cell tab design with a heat-rejecting lead tab made of thermally-conductive material, which covers the electrode tab and main electrode layer surface areas, facilitating both in-plane and through-plane heat transfer by being directly coupled and welded to the electrodes, allowing for efficient heat rejection to a cooling plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cooling methods are used for lithium-ion pouch battery cells, then the cell structure remains simple and manufacturing is easier, but heat management during fast charge events is inadequate leading to reduced performance and longevity

Engineering Contradiction:

Improveheat management effectivenessVSAvoidcell structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooling function is merged with the existing tab structure by integrating a heat-rejecting lead tab that serves both as an electrical conductor and a thermal management component. This eliminates the need for separate cooling structures while achieving effective heat rejection during fast charge events.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lead tab is designed to perform multiple functions simultaneously: it serves as an electrical connection point for current collection and as a thermal conduction path for heat rejection. This multi-functional design improves heat management without adding separate dedicated cooling components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a heat-rejecting lead tab is added to cover the electrode tab and main electrode layer, then heat transfer efficiency is improved, but the manufacturing process and assembly complexity increase

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidassembly process simplicity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heat-rejecting lead tab is designed with segmented geometry including a main lead body and a heat-rejecting protrusion that covers specific areas of the electrode tab and main electrode layer. This segmentation allows optimized thermal contact with different heat-generating regions while maintaining manufacturability through standard forming processes.

Inventive Principle:

Principle #1Segmentation

3Temperature

If the heat-rejecting lead tab is directly coupled and welded to the electrodes, then thermal conduction is enhanced, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvethermal conduction effectivenessVSAvoidwelding alignment precision

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The heat-rejecting lead tab is pre-formed with the protrusion geometry and thermal conduction paths before assembly. This preliminary preparation ensures proper alignment and contact with the electrode tab and main electrode layer, reducing the precision requirements during the welding operation while maintaining effective thermal conduction.

Inventive Principle:

Principle #10Preliminary action

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 design enables effective cooling of lithium-ion pouch battery cells during fast charge events, maintaining cell assembly integrity and performance while allowing for direct tab cooling, thus enhancing thermal management and extending the battery's lifespan.

Implementation Method 1

The heat-rejecting lead tab comprises a thermally-conductive material and facilitates heat transfer from the electrode stack to the heat-rejecting lead tab

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The heat-rejecting protrusion is welded to the electrode tab of one of the plurality of electrodes

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS10680297B2Tab cooling for pouch cell

Publication Date: 2020.06.09 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A lithium-ion pouch battery cell includes a plurality of electrodes stacked together to form an electrode stack. Each of the electrodes includes a main electrode layer and an electrode tab protruding from the main electrode layer. The electrode stack has a tab surface area, and the main electrode layer has a main surface area. The lithium-ion pouch battery cell further includes a heat-rejecting lead tab coupled to the plurality of electrodes. The heat-rejecting lead tab covers the tab surface area of the electrode tab and the main surface area of the main electrode layer to facilitate heat transfer from the electrode stack to the heat-rejecting lead tab.