Hexagonal Battery Cell Assembly for Dense Packing and Cooling
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Solution Overview
Problem
The challenge is to increase energy density and improve cooling efficiency in battery modules by using hexagonal prism-shaped battery cells while preventing electrode active material damage or separation at the edges during manufacturing.
Innovation Solution
A hexagonal prism-shaped battery cell with an electrode assembly featuring a hollow structure and a cell case of the same shape, where the electrode active material is coated discontinuously at predetermined intervals on the current collectors, allowing for bending at uncoated regions to prevent damage, and a method involving winding a stack structure of electrodes and a separator to form the hexagonal prism shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cylindrical battery cell is used, then the manufacturing process is simple, but the empty space between adjacent battery cells increases resulting in low energy density
Solution Approach 1:
The patent applies the principle of changing geometric form from cylindrical to hexagonal prism shape. This curvature modification allows the battery cells to pack more efficiently in space, eliminating empty gaps between adjacent cells while maintaining manufacturing feasibility through adapted electrode assembly processes
2Temperature
If a cooling plate is interposed between cylindrical battery cells, then cooling is provided, but the contact area between the battery cell and the cooling plate is narrow resulting in low cooling efficiency
Solution Approach 1:
The hexagonal prism shape provides flat side surfaces that enable maximum contact area with cooling plates. The geometric modification from cylindrical to hexagonal form allows cooling plates to be positioned against the flat sides, significantly increasing the thermal contact area and improving heat dissipation efficiency
3Stability of the object's composition
If the electrode active material is continuously loaded on the electrode current collector, then the electrode structure is complete, but the electrode active material is bent and damaged at the edge of the hexagonal prism resulting in degradation
Solution Approach 1:
The patent segments the continuous electrode active material into discrete blocks with intervals between them. This segmentation allows the electrode assembly to be bent at the interval regions without damaging the active material blocks, preventing cracking and peeling that would occur with continuous loading during the hexagonal prism forming process
Solution Approach 2:
The interval regions between electrode active material blocks serve as intermediary zones that accommodate the bending required to form the hexagonal prism shape. These intermediary spaces act as buffer zones that protect the fragile active material from mechanical damage during assembly
Data Source
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AI summary
A battery cell according to an embodiment of the present disclosure includes an electrode assembly having a hollow structure with a hexagonal prism-shaped hole at a center, wherein an exterior of the electrode assembly is in a shape of a hexagonal prism, and a cell case in which the electrode assembly is received, wherein an exterior of the cell case is in a shape of a hexagonal prism.